Field of the invention
[0001] The present invention relates to a reflective optical element for reflecting light
in a wavelength range less than 50 nm in an EUV-lithographic projection exposure system.
Further, it relates to an EUV projection lens of an EUV-lithographic projection exposure
system and to a method to configure an EUV projection lens.
Background art-The EUV-lithographic projection exposure system
[0002] To reduce the size of micro-structured devices like semiconductor circuits (e.g.
integrated, analogue, digital or memory circuits, thin-film magnetic heads) with the
technique of optical lithography the optical resolution limit of optical microlithographic
projection exposure systems must be further improved. Due to diffraction, the resolution
limit in a first order approximation is inverse proportional to the numerical aperture
of the projection lens of the microlithographic projection exposure system, with which
structures are projected from a mask onto a substrate by a projection beam, to form
the micro-structured devices there, e.g., by exposure of a light sensitive resist
(which covers the substrate) with at least parts of the projection beam. For this
reason, one focus is to increase the numerical aperture of the projection lens. Another
focus is to reduce the used wavelength for the projection process, since the optical
resolution limit is also proportional to this wavelength. For this reason the historical
development of optical lithography systems was such that the wavelength of the used
light in the projection process was reduced from visible light to ultraviolet light
and now to
Very Deep
Ultra
Violet light (
VUV light, like 193 nm which is produced e.g. by an advanced ArF excimer laser). Now
VUV lithography is broadly used in mass production of semiconductor circuits. Today,
mass production of high integrated circuits is mostly done on microlithographic projection
exposure systems with a projection light of the mentioned wavelength of 193 nm, whereas
the numerical aperture NA of the projection system which projects the structures on
a mask (or structured object) onto a substrate, is much more than 1.0, even more than
1.3. Such high numerical apertures only can be achieved by the use of immersion systems.
The principles of such systems are already described e.g. in
DD 221563 A1 or in
US 2006092533 A1.
[0003] For an onward reduction of the size of the micro-structured devices, a further reduction
of the wavelength of the projection light is necessary. Since in the very deep ultraviolet
wavelength range almost all optical materials become opaque, there are no suitable
materials for optical lenses for wavelength below about 157 nm. Using even shorter
wavelengths for the projection light, the projection lenses can only work with reflective
optical elements like mirrors or like diffractive optical elements. During the last
years, enormous efforts were done to develop optical microlithographic projection
exposure systems, which use for the projection process wavelengths less than 50 nm.
Systems working with a projection wavelength between 10 nm and 14 nm are described
e.g. in
EP 1533832 A1 or in
US 20040179192 A1. Depending on the light sources which are available for the projection light of such
short wavelengths, the wavelengths for the projection light may be even 5 nm or less.
At such short wavelengths of less than 50 nm or even much shorter, the projection
lenses of the optical microlithographic projection systems comprise only reflective
optical elements like mirrors and/or diffractive structures like reflective diffractive
structures. Projection systems which are working at a wavelength of less than about
50 nm are known as EUV (
Extreme
Ultra
Violet) lithographic projection exposure systems.
[0004] A simplified EUV lithographic projection exposure system 100 is schematically shown
in Fig. 1. The system comprises an EUV light source 1, producing EUV light with a
significant energy density in the extreme ultraviolet or EUV spectral region, especially
in the wavelength range less than 50 nm, preferably in a range between 5 nm and 15
nm. Discharged-produced or laser-produced plasma light sources are used as EUV light
sources, making use of e.g. xenon, tin or lithium plasma which generates the extreme
ultraviolet light. Such sources irradiate unpolarized light under about 4 π solid
angle. Other sources generate a spatially more directed and a more polarized beam
of extreme ultraviolet light like e.g. synchrotron radiation sources. Dependent on
the EUV light source 1, especially if an EUV plasma light source is used, a collector
mirror 2 may be used to collect the EUV light of the light source 1 to increase the
energy density or irradiance of the EUV radiation and form an illumination beam 3.
The illumination beam 3 illuminates via an illumination system10 a structured object
M. The structured object M is e.g. a reflective mask, comprising reflective and non-reflective
or at least minor reflective regions to form at least one structure on it. Alternatively
or additionally, the structured object comprises or consists of a plurality of mirrors
which are arranged about side by side in at least one dimension to form a mirror arrangement
like a mirror array. Advantageously the mirrors of the mirror array are adjustable
around at least one axis to adjust the incidence angle of the illumination beam 3
which is irradiated on the respective mirror.
[0005] It shall be understood that the terms reflective, minor reflective and non-reflective
relates to the reflectivity of EUV light of the illumination beam 3. Due to the very
short wavelength of the EUV light, the reflective surfaces are usually coated if the
angle of incidence for the EUV light is less than about 45°. The coatings preferably
comprise a multilayer of predetermined layer materials with predetermined layer thicknesses.
Such mirrors are usually used for incidence angles less or far less than 45° down
to about 0°. For such mirrors a reflectivity of more than 60% can be achieved due
to a constructive interference of the reflected EUV light which is partially reflected
at the various material boundaries of the individual layers of the multilayer. A further
advantage of such multilayer-coated reflective mirrors or surfaces is their property
to work as a spectral filter, to make e.g. an illumination and/or projection beam
of the EUV lithographic projection system more monochromatic. In an EUV lithographic
projection exposure system coated mirrors are sometimes also designated as normal
incidence mirrors.
[0006] For larger incidence angles than about 45°, especially for much larger incidence
angles like angles of about 70° and even more, it is sufficient if the reflective
surface comprises a metal or a metal layer like Ruthenium, or if the reflective surface
consists of a metal or a metal layer, comprising e.g. Ruthenium. At such high incidence
angles, the reflectivity can be increased up to 60% and more without the necessity
of a multilayer as mentioned above. As a general rule the reflectivity increases with
increasing angle of incidence, which is why these mirrors are also called grazing
incidence mirrors. EUV lithographic projection exposure systems often use plasma light
sources. In this case, the collector mirror 2 can be a grazing incidence mirror as
described e.g. in
WO 2002/065482 A2 or
US 2004/0130809 A1.
[0007] The structured object M reflects parts of the illumination beam 3 into a light path
which forms a projection beam 4. The structured object M structures the illumination
beam 3 after being reflected on it, depending on the structure on the mask M. This
projection beam 4 is carrying the information of the structure of the structured object
and is irradiated into a projection lens 20 such that at least two diffraction orders
of the structure or the structures of the structured object M pass the projection
lens 20 and form a kind of an image of the structure or the structures of the structured
object M on a substrate W. The substrate W, e.g. a wafer, comprising a semiconductor
material like silicon, is arranged on a substrate stage WS which is also called wafer
stage.
[0008] In addition to the information about the structure of the structured object M, the
projection beam also comprises information about the illumination condition of how
the structured object M is illuminated regarding angular, polarization and intensity
(or radiation power per unit area) in an object point OP of the structured object
M, and of how these parameters are distributed over the illuminated surface of the
structured object M. The kind of illumination is expressed by the term "setting".
This means a predefined angular and/or polarization and/or intensity distribution
with which an object point OP on the structured object M is illuminated, and how these
distributions depend on the spatial position on the structured object M. The setting
also influences the optical resolution of the projection process which is done by
the projection lens 20. In general, the optical resolution can be increased if the
setting is adapted to the shape of the structure on the structured object M. Advanced
illumination techniques which use adapted settings for the illumination of a structured
object are described e.g. in "
Resolution Enhancement Techniques in Optical Lithography" by Wong, Alfred Kwok-Kit;
ISBN 0-8194-3995-9". The kind of illumination, the setting, can be adjusted with the illumination system
10 (see Fig. 1), which comprises a plurality of mirrors 12,13, 14, 15, 16.
[0009] In Fig. 1, as an example, the projection lens 20 schematically shows four mirrors
21, 22, 23 and 24 as reflective optical elements to form a kind of an image of the
structure of the structured object M on the wafer W. Such EUV projection lenses 20
typically comprise 4 to 8 mirrors. However, projection lenses with only two mirrors
may also be used. These mirrors are made with highest precision regarding surface
figure (or regarding their geometrical form) and surface roughness. Each deviation
from the desired specification results in a degradation of the image quality on the
substrate or wafer W. Usually the specification is such that a deviation from the
surface figure (the required or specified dimensions of the shape of the surface)
of less than one tenth of the used projection wavelength is required. Depending on
the used wavelength the surface figures of the mirrors 21, 22, 23and 24 must be made
with a precision of even better than 1 nm, for some mirrors the precision requirements
are even a factor of 5 to 20 higher, ending up at precision ranges of much smaller
than one atom layer, which means better than 0.1 nm. To project structures from a
mask to a substrate with the EUV lithographic projection technique in such a way that
the image on the substrate comprises structures down to about 10 nm of lateral dimension
or even structures with smaller lateral dimensions the optical aberration of the projection
lens 20 must be smaller than 1 nm, even smaller than 0.1 nm or smaller than 50 pm
(picometer) of RMS value. This means that the root-mean-square (RMS) value of the
deviation of the real wavefront from the ideal wavefront is smaller than the mentioned
values. This very high precision regarding the surface shape (surface figure or geometrical
form) must be kept over a mirror dimension of more than 10 cm. Modern EUV projections
lenses comprise mirrors of a diameter of 30 cm or even more with such a high requirement
regarding the surface figure. This very high mechanical precision is necessary to
form an image point IP on the substrate W from an illuminated object point OP on the
structured object M by illuminating the object point OP with a well configured illumination
beam according to a predetermined setting.
[0010] Further, to project the illuminated object point OP with the projection lens 20 with
at least parts of the projection beam 4 onto the substrate W, the projection beam
4 is generated by the illumination beam 3 and the diffracting properties of the structured
object M. One necessary condition to form an image on the substrate W is that the
diffracted wave fronts, which are coming from an object point OP, interfere in the
image point IP on the substrate or wafer W. To get a good image quality the interfering
wave fronts must have a relative phase shift of far less than one wavelength of the
projection beam light. Due to the various illumination settings, of how the structured
object M can be illuminated by the illumination beam 3, the light path of the light
passing one object point OP on the structured object M can vary within the projection
lens 20 in such a way that light bundles of the projection beam 4 are reflected by
the mirrors 21, 22, 23, 24 of the projection lens 20 at different surface areas with
different sizes. This variation depends on the illumination settings and the position
of the mirrors 21, 22, 23, 24 within the projection lens 20. To make sure that the
image quality is achieved under all illumination settings it is necessary that the
above-mentioned surface figure is achieved with the mentioned high mechanical precision.
[0011] Apart from the high mechanical precision of the surface figure of the mirrors 21,
22, 23, 24 in the projection lens 20, also the position and orientation of these mirrors
21, 22, 23, 24 relative to each other, relative to the structured object M and relative
to the substrate W must be in the same range of accuracy. This means that position
and orientation of these objects (mirrors 21, 22, 23, 24, structured object M and
substrate W) must be adjusted also in the nanometer range or even below. In addition,
a metrology is necessary to allow the manufacturing of such precise mirror surfaces,
the assembling of the projection lens of the EUV lithographic projection system, the
integration of the assembled projection lens into the projection system, and to allow
any in-situ monitoring and control of the system during the operation of the system.
[0012] To achieve the above mentioned mechanical precisions, one further problem is the
absorption of the projection beam 4 by the mirrors 21, 22, 23, 24. This absorption
which could be in a range of up to 30% heats the mirrors. Depending on the absorbed
heat each mirror may be deformed due to thermal expansion of the mirror. One method
to reduce such thermal effects during the projection step, when a certain amount of
the projection beam 4 is absorbed, is to use a temperature control system to keep
the very high mechanical precision data as mentioned above, especially for the surface
figure of the mirrors. Another or an additional method is to use as a mirror material
or as a support structure for the mirror a low thermal expansion material with such
a small coefficient of thermal expansion (CTE) like 5 ppb/K (or less) to reduce deformations
of the mirror, if the temperature changes e.g. due to partial absorption of the projection
beam 4. This method and the selection of appropriate materials with the respective
small CTE and the control of the mirror temperature is described e.g. in
US 7,295,284 B2.
[0013] EUV lithographic projection exposure systems like shown in Fig. 1 are usually operated
under vacuum conditions. The projection lens 20 and/or the illumination system 10
are operated under reduced pressure or vacuum. Usually the pressure conditions in
the illumination system and the projection lens are different. The reduced pressure
or vacuum conditions significantly reduce the technical solutions for the above mentioned
problems regarding the deformation of mirrors and their active or passive position
control. Especially temperature control systems for controlling a temperature of components
inside the EUV lithographic projection exposure system are quite often limited to
certain technical solutions which are not essentially based on thermal convection
principles.
Summary of the invention
[0014] The present invention is directed to an improved EUV-projection lens to further reduce
the influence of any temperature variation to deformations and/or position variations
of the reflective optical elements or mirrors inside such a projection lens.
[0015] A projection lens of an EUV lithographic projection exposure system in accordance
to this invention comprises mirrors and a supports structure to support or suspend
the mirrors. In the vicinity of a mirror the support structure is at a reference temperature.
Preferably the reference temperature is the same for all support structure parts which
are close to the mirrors, and the mirrors are also at this reference temperature if
they are not subjected to any radiation like EUV light. Further, the projection lens
comprises a heater and temperature control system to control the temperature of at
least one heatable mirror. Without heating the heater the mirrors warm up from the
reference temperature by an average temperature if the projection lens is exposed
with the exposure power of the EUV light which is used to project an object field
onto an image field. More precisely, during such an exposure a temperature distribution
is formed out on the mirror which differs from the constant temperature of the reference
temperature. This temperature distribution is characterized e.g. by the average temperature
or by a maximum temperature. Further, in the projection lens of this invention the
at least one heatable mirror comprises a body which comprises a material with a temperature
dependent coefficient of thermal expansion which is zero at a temperature T
0k (called zero cross temperature). The zero cross temperature is selected such that
it is higher than the reference temperature. According to this invention the heatable
mirror is heated and controlled to a temperature selected from a group of determined
temperatures before the formation of the temperature distribution which is caused
by the exposure power of the EUV light. This has the advantage that the warm up time
(if the mirror is exposed with the exposure power of the EUV light) of the heatable
mirror is significantly reduced. Further, the determined temperatures are selected
such that the average temperature of the mirror after the warm up is close to or at
the zero cross temperature. This means the in a steady state condition the at least
one heatable mirror has a temperature at or close to the zero cross temperature. Preferably
more than one mirror of the projection lens is heatable.
[0016] A further projection lens, called first projection lens, of this invention comprises
at least two mirrors with mirror bodies wherein each body comprise a material with
a temperature dependent coefficient of thermal expansion which is zero at respective
zero cross temperatures Tom, Ton . The absolute value of the difference between these
zero cross temperatures Tom, Ton is more than 6K and the lens is designed to be exposed
with an exposure power of more than 8W of EUV light with a wavelength in a wavelength
range of less than 50 nm. The selection of materials which widely differ regarding
their respective zero cross temperatures advantageously offer the possibility to make
projection lenses for higher exposure powers without the drawback that the thermal
induced aberration of the mirrors is increasing. This offers the possibility to manufacture
EUV projection lenses with minimal aberration and high exposure power.
[0017] In a further projection lens, called second projection lens, according to this invention
the materials of the mirror bodies or substrates are selected according to a rule
which is also part of this invention. At least one material is selected in such a
way that its zero cross temperature is above the largest temperature value which the
mirror can get under operation. With an additional heater the mirror is warmed up
to the zero cross temperature or close to it which results in minimal thermal aberration.
The advantage of the second projection lens is that the lens is very insensitive regarding
the selected exposure power, any manufacturing tolerances of the zero cross temperature,
any selected illumination settings and any mask patterns.
[0018] In a further projection lens, called third projection lens, according to this invention
for at least two mirrors one material for the mirror bodies is selected. This material
has a temperature dependent coefficient of thermal expansion which is zero at least
two zero cross temperatures T
10mn and T
20mn. The projection lens is designed such that one of the two mirrors is operated at
or close to the first zero cross temperature T
10mn and the other mirror is operated at or close to the second zero cross temperature
T
20mn, if the projection lens is subjected to the EUV exposure power which is necessary
for the projection process in mass production. The advantage of the third projection
lens is that the lens needs fewer different substrate materials for its mirrors.
[0019] Further, the present invention relates to a method to configure a EUV projection
lens. Especially the method focuses on the selection of suitable materials for the
mirror bodies such that the thermal aberration of the lens can be minimized.
[0020] Further aspects of the invention are to provide various heating means or tempering
means with which the mirrors in an EUV projection lens can be heated or cooled. These
means also comprise mirror bodies with characteristic features like coatings or shapes
which improve the temperature control of the respective mirror during its operation
in the projection lens.
[0021] In general the above mentioned mirrors of the EUV projection lens shall also comprise
any reflective elements like reflective diffractive structures, since the teachings
of the present invention are not limited to mirrors.
[0022] Further features and advantages of the present invention and further improvements
will become apparent from the following detailed description of exemplary embodiments
with reference to the following figures in which like reference characters designate
the same or similar parts. However, the following description of the invention by
exemplary embodiments is merely illustrative and in no way intended to limit the invention
and its applications. As shown in this description, features of different embodiments
can be exchanged and/or combined to get additional embodiments of the present invention.
Brief description of the Drawings
[0023]
- Figure 1
- schematically shows a simplified EUV lithographic projection exposure system with
an illumination system and an EUV projection lens which comprises four mirrors.
- Figure 2a
- linear expansion coefficient (CTE) for various materials as a function of temperature.
The materials have a zero cross temperature for which this coefficient is zero. (from
Critical Reviews of Optical Science and Technology, Vol. CR43, p 183, article from S. F. Jacobs "Variable invariables - dimensional instability with time and temperature";
ISBN 0-8194-0953-7; 1992)
- Figure 2b
- Linear expansion coefficient for various Zerodur® materials as a function of temperature
with various zero cross temperatures where this coefficient is zero. (from Critical Reviews of Optical Science and Technology, Vol. CR43, p 186, article from
S. F. Jacobs "Variable invariables - dimensional instability with time and temperature";
ISBN 0-8194-0953-7; 1992)
- Figure 3a
- schematically shows a side view of a reflective optical element like a mirror at two
different temperatures.
- Figure 3b
- schematically shows a deformation of a mirror surface due to temperature variations
along the x-axis of the mirror.
- Figure 3c
- schematically shows a relative change of a length ΔL/L0 of a body with a length Lo as a function of temperature in units of ppb for Zerodur®
and ULE®.
- Figure 3d
- show a temperature distribution on the 4th mirror of the EUV projection lens of Fig. 6 together with the mirror size.
- Figure 3e
- shows the temperature profile of the mirror of Fig. 3d along the x-direction trough
the temperature maximum. The temperature difference to the reference temperature is
given.
- Figure 3f
- shows the temperature profile of the mirror of Fig. 3d along the y-direction trough
the temperature maximum. The temperature difference to the reference temperature is
given.
- Figure 3g
- shows values of the Zernike-coefficients for the mirror M4 of Fig. 3d to Fig. 3f in relative units.
- Figure 3h
- show a temperature distribution on the 6th mirror of the EUV projection lens of Fig. 6 together with the mirror size.
- Figure 3i
- shows the temperature profile of the mirror of Fig. 3h along the x-direction trough
the temperature maxima. The temperature difference to the reference temperature is
given.
- Figure 3k
- shows the temperature profile of the mirror of Fig. 3h along the y-direction trough
the minimum temperature between the maxima in the x-direction. The temperature difference
to the reference temperature is given.
- Figure 3l
- shows values of the Zernike-coefficients for the mirror M6 of Fig. 3h to 3k in relative units.
- Figure 4
- schematically shows a mirror mounting assembly with a mirror as used in a projection
lens of an EUV-lithographic projection exposure system as described in e.g. in WO 2005/026801 A2.
- Figure 5
- schematically shows the mirror mounting assembly of Fig. 4 with a heater for heating
the mirror and a temperature control system for controlling the temperature of the
mirror.
- Figure 6
- schematically shows an EUV projection lens which comprises 6 mirrors, a heater and
a temperature or aberration control system for the sixth mirror.
- Figure 7
- shows an example for a warming-up of the six mirrors of the projection lens shown
in Fig. 6, if such a lens is exposed with an EUV projection beam which has a power
of 16 W after the reticle M.
- Figure 8
- shows the aberration for each mirror of the projection lens of Fig. 6 expressed by
the Zernike-coefficient Z5. Z5 is given by its RMS (root mean square) value as a function
of the zero cross temperature when each mirror of the projection lens is in the steady
state as described in Fig. 7.
- Figure 9
- shows the optimized zero cross temperature as a function of the EUV light power P
after the reticle M to which the EUV lens of Fig. 6 is subjected during a projection
process.
- Figure 10
- schematically shows a side view of a reflective optical element Mk like a mirror of an EUV projection lens as shown in Fig. 4 and Fig. 6. Further, a
heater and a cooler are arranged nearby the mirror which is supported by supporting
elements.
- Figure 11
- schematically shows a side view of a reflective optical element as shown in Fig. 10
but without the heater. The temperature of the reflective optical element or mirror
Mk, 421 is controlled by a pressure control of the pressure within the direct surrounding
area or volume of the reflective element or mirror.
- Figure 12a
- shows the transmission of Zerodur® for a transmission path of 5 mm and of 25 mm.
- Figure 12b
- schematically shows a reflective optical element or a mirror Mk, 421 which is coated with a coating C on almost its entire surface to make the mirror
heatable with IR radiation.
- Figure 12c
- schematically shows a reflective optical element or a mirror Mk, 421 which is at least partly coated with a coating C2 on its surface to make the
mirror heatable. The coating C2 is selected such that it will have a certain electrical
resistance.
- Figure 12d
- schematically shows a reflective optical element or a mirror Mk, 421 which is at least partly heated by a multi-zone wire grid 1050 which is arranged
nearby the reflective surface MSk.
- Figure 13
- schematically shows several embodiments of heaters or tempering means 300 in relation
with a reflective element or mirror Mk, 421.
Detailed description of the embodiments
[0024] To reduce deformation or position variation of the mirrors or the reflective optical
elements inside a projection lens 20 (see Fig. 1 as described above) and to achieve
the surface figure accuracy and position accuracy in the range of 0.1 nm or even better,
any thermal expansion must be minimized. This means that the actual surface data regarding
the surface shape of a mirror and its actual position data must be within the specified
range relative to a required or specified dimension of the shape of the surface of
the mirror and relative to its required or specified position. With such optical elements
in a projection lens image structures down to about 10 nm of lateral dimension or
even structures with smaller lateral dimensions can be generated. Further, for such
optical elements (mirrors) or for the projection lens the optical aberration is smaller
than 1 nm, even smaller than 0.1 nm or smaller than 50 pm (picometer) of RMS value.
This means that the root-mean-square (RMS) value of the deviation of the real wavefront
from the ideal wavefront is smaller than the mentioned values. To minimize thermal
expansion of the optical element which result in a reduction of the thermal induced
optical aberration, the body MB
k of at least one mirror or reflective optical element k of the plurality of reflective
optical elements M
i of the projection lens is made of a material or comprises a material with a temperature
dependent coefficient of thermal expansion (CTE) which is zero at a temperature T
0k. This temperature T
0k is called zero cross temperature. Examples of such materials are shown in Fig. 2a
and 2b. The application of such materials in EUV lithographic projection exposure
systems is e.g. described in
WO 2004/015477 A1. Depending on the operation temperature of the lithographic projection exposure system
100, or the operation temperature of the reflective optical elements of such a system,
there are different materials available which have at least one zero cross temperature
To. Since the usual operation temperature of the reflective optical elements is in
the range of about 0°C up to about 100°C, preferably in the range of about 10°C to
about 60°C, better in a range of about 20°C to about 40°C, the number of available
materials is very restricted.
[0025] According to Fig. 2a Superinvar (an alloy of Fe-Ni-Co) or ULE® (a registered trademark
of Corning Inc.) are suitable materials, or according to Fig. 2b a material made of
a Zerodur® (a registered trademark of Schott AG) type may be chosen which is made
of a glass ceramic. ULE® is a Titania silicate glass, which is a vitreous mixture
of SiO
2 and TiO
2. In a first order approximation the CTE-value of ULE® and Zerodur® near by the respective
zero cross temperatures can be approximated by the equation CTE(T) = a1 (T-To), see
e.g. Fig. 2a and Fig. 2b. For ULE® the constant or lope a1 is positive. This means
that the material shrinks with increasing temperature if the temperature T of the
material (made of ULE®) is below T
0, and the material expands if its temperature T is above T
0. For Zerodur® the constant or slope a1 is negative in the range of room temperature,
as it is shown in Fig. 2b. This means that the material expands with increasing temperature
if the temperature T is below T
0, and the material shrinks if the temperature is above T
0. At higher temperatures there is a second zero cross temperature T
20 with a positive constant or slope a2 in the approximation CTE(T) = a2 (T-T
20). This means that the material behaves similar like ULE® regarding thermal shrinkage
and thermal expansion. In a certain temperature range around the zero cross temperature
ULE® and Zerodur® have a CTE-value in the range of ppb/K (10
-9/K) down to zero. This means that a body of e.g. about 100 mm thickness which is made
of a material with a CTE-value of about 1 ppb/K expands or shrinks of about 0.1 nm
if the temperature changes by one Kelvin (1K). For Superinvar the temperature range
around the zero cross temperature must be much smaller to achieve an effective CTE-value
of 1 ppb/K. This result in extra efforts regarding the temperature control system
which is one aspect why Superinvar is less preferred than ULE® and/or Zerodur® to
use it as a substrate material for reflective optical elements in EUV lithography,
especially in a projection lens 20 of an EUV lithography exposure system 100.
[0026] In general, thermal or temperature variations influence the aberration or image defects
of an optical imaging system. However, an overall change or homogenous change in temperature,
e.g. by a temperature offset ΔT of the spatial temperature distribution which changes
the temperature from T(x,y,z) to T(x,y,z)+ ΔT (x, y and z designate the spatial coordinates),
has only a small impact to refractive lens elements, which are used in VUV lithography.
This is because the refractive power changes overall in the lens element and the changes
of the surface figures of the refractive lens is negligible due to the almost constant
coefficient of thermal expansion (CTE) of the refractive material.
[0027] In an EUV-lithographic projection system in which reflective optical elements like
mirrors are made of materials, as e.g. shown in Fig. 2a and Fig. 2b, which comprise
a coefficient of thermal expansion CTE(T) which strongly depends on the temperature
T, even a homogeneous change in temperature as mentioned has a strong influence onto
the aberration values of the optical system. This is schematically explained in more
detail with Fig. 3a and Fig. 3b on the basis of the inventors' analyses.
[0028] Fig. 3a schematically shows a side view of a reflective optical element like a mirror
M
k with a body MB
k and a reflective surface MS
k. The mirror M
k has a spatial temperature distribution T(x,y,z). If the mirror body MB
k comprises material with a zero cross temperature then usually the temperature distribution
T(x,y,z) is different from the zero cross temperature. If the temperature distribution
is changed by a constant value ΔT, then, if e.g. the temperature is raised closer
to the zero cross temperature, the mirror will expand to the mirror M
k* with body MB
k*, if e.g. Zerodur® is used in a temperature regime in which the slope a2 (in the
approximation CTE(T) = a2 (T-T
20)) is negative. However, despite the expansion in a first approximation the surface
figure of the surface MS
k does not change its shape, but the surface MS
k* of the expanded mirror M
k* changes its position. It is shifted e.g. into the z-direction by a value Δz as shown.
This change in position of the reflective surface can be easily corrected by a translational
movement of the heated mirror M
k*. In this case the image defects or the optical aberration is almost unchanged.
[0029] Fig. 3b schematically shows the situation of the mirror M
k with a temperature distribution T(x,y,z) = T
Ref (which is called reference temperature). Further, as an example, the mirror is locally
heated in a surface area from x1 to x2 along the x-dimension of the mirror body MB
k, as shown by the temperature profile or temperature distribution ΔT(x) which is added
to the reference temperature T
Ref, having a maximum temperature ΔT
max. In this case the reference temperature T
Ref means that at this temperature the mirror has reference shapes, also its reflective
surface MS
k has a reference surface figure. Any deviation due to thermal expansion is related
to these reference shapes and the surface figure. It is further assumed that the interval
[x1, x2] is small compared to the dimension of the mirror body in the x-direction.
If the mirror body is heated up from the reference temperature T
Ref by the temperature profile ΔT(x), and if it is made of a material with a temperature
dependent coefficient of thermal expansion which is zero at a temperature To , like
Zerodur® or ULE® as shown in Fig. 2a and Fig. 2b, and if the maximum temperature of
the mirror body, given as T
Ref+ ΔT
max,, as an example is below the zero cross temperature To and above the reference temperature
T
Ref due to the heating, then the reflective surface of the mirror between the coordinates
x1 and x2 will shrink compared with the surface at the reference temperature. This
is the case if e.g. ULE® is used. In Fig. 3b the change in surface figure is schematically
shown by MS
k* which can be compared with the reference surface figure MS
k at the reference temperature T
Ref. L1 and L2 designate the coordinates of the body at the reference temperature T(x,y,z)
= T
Ref which result in a length of the body L
0(T
Ref) = (L2-L1) in the x-direction. To explain this deformation in more detail reference
is made to Fig. 3c.
[0030] Fig. 3c schematically shows the relative change of a length of the body MB
k ΔL/L
0 with a length Lo (like the one mentioned in connection with Fig. 3b) as a function
of temperature in units of ppb (parts per billion, meaning in values of 10
-9). As a reference temperature T
Ref = 22°C is chosen. This means that the length Lo is the length at 22°C. The zero cross
temperature T
0k is, as an example, set to 25°C which is 3K higher that the reference temperature.
Curve 301 schematically shows the relative length changes for ULE®, and curve 302
schematically shows the situation for a Zerodur® material, selected such to also have
a zero cross temperature To at about 25°C and to have a negative slope a1 for the
CTE approximation CTE(T) = a1
∗ (T - T
0). If e.g. the mirror body MB
k is made of ULE® and the temperature of the mirror body is selected within the temperature
interval T
Ref and (2T
0k - T
Ref) then the mirror body will shrink relative to the mirror body at the reference temperature.
In the case that the mirror body is made of Zerodur®, see curve 302,then the mirror
body will expand relative to the body at the reference temperature, as can be seen
from Fig. 3c. If the mirror surface has a temperature profile similar like shown in
Fig. 3b then (in a first approximation) the mirror surface regions between L1 and
x1 are not changed due to thermal expansion. Also the region between x2 and L2, since
there the temperature is at the reference temperature or close to it. In the region
between x1 and x2 the mirror body will expand or shrink because the temperature is
different from the reference temperature. Whether expansion or shrinkage occurs in
this region depends on the material and on the relative position of the absolute temperature
profile ΔT(x) +T
Ref and the zero cross temperature T
0k to each other. The average temperature ΔT
av of the temperature profile is given as ΔT
av = (∫ΔT(x) dx|
x2x1)/(x2-x1) with the integration limits x1 and x2. Is the absolute temperature profile
ΔT(x) +T
Ref about equal to the zero cross temperature T
0k then there is no expansion or shrinkage of the interval [x1, x2]. However, within
this interval there is still surface deformation (not shown in Fig. 3b) possible on
a scale lower than this interval, if there are local temperature variation of the
temperature profile ΔT(x). In the case T
av + T
Ref = T
0k the surface figure deformation is minimized and on the scale of the interval [x1,
x2] it can be neglected. In this case the aberration or image defects are minimized.
In the other case if the average temperature is not the zero cross temperature and
if the mirror body MB
k shrinks within the interval [x1, x2] then the surface figure of the reflective surface
changes as schematically shown in Fig. 3b, designated as MS
k*. In the case of expansion the reflective surface changes to MS
k** which also results in a change of surface figure. In both cases aberration and
imaging defects will increase. In Fig. 3b, as an example, the absolute average temperature
is below the zero cross temperature but within the reference temperature T
Ref and a temperature given by 2T
0 - T
Ref, resulting in a surface deformation MS
k* for ULE® and a surface deformation MS
k** for Zerodur® for the mirror body MB
k of Fig. 3a. It shall be mentioned that if the mirror is homogenously headed to about
the temperature T = (2To - T
Ref) then the mirror has the same dimensions and surface figures as at the reference
temperature T
Ref which results in no additional aberration or image errors caused by the heating.
In the above simplified explanation of the influence of the thermal expansion to aberrations
there are various simplifications like the special temperature profile, the assumption
that there is only a temperature variation in x-direction and the other dimensions
remain at the reference temperature T
Ref, and that the mirror body is made of a material which has no variations in the zero
cross temperature which means that the zero cross temperature does not vary in the
x-, y- and z-direction of the mirror. For practical designs more complex simulation
calculations or finite element calculations are necessary to optimize a reflective
surface and other mirror parameters like the zero cross temperature or the operation
temperature of the mirror which is operated under a given thermal load.
[0031] According to the present invention the operation temperature of the mirror and the
zero cross temperature shall be selected such that the absolute temperature profile
ΔT(x,y,z) + T
Ref which differs from the reference temperature T
Ref(x,y,z) of the mirror or reflective optical element should be symmetric about the
zero cross temperature To . For one dimension, e.g. in x-direction, this means as
ΔT
av + T
Ref = (∫ΔT(x) dx|
x2x1)/(x2-x1) + T
Ref = T
0.
[0032] If the temperature profile ΔT varies in more than one dimension, e.g. if ΔT = ΔT(x,y,z),
then the integration is done in each dimension to get the average temperature, meaning
T
av = (∫∫∫ ΔT(x,y,z) dxdydz|
x2x1|
y2y1|
z2z1)/(x2-x1)/(y2-yl)/ (z2-z1) in which y1, y2 and z1, z2 are the respective mirror edges
in the y- and z-direction. Alternative, an average temperature for each dimension
is separately calculated. In this case the optimization to the zero cross temperature
can be done to an individual average temperature or to two individual average temperatures,
which are related to the dimension or to the dimensions which are most relevant for
the aberration.
[0033] Further, in accordance with the invention the optimization of the zero cross temperature
may be adapted to the expected absolute average temperatures ΔT
av + T
Ref = T
0 for each mirror of the EUV projection lens which has a zero cross temperature. Alternative,
the expected absolute average temperatures are homogenously raised to the zero cross
temperature of the mirror material by e.g. homogenously heating the mirror body in
at least one dimension with a heating means. Since the last method offers more flexibility
it will be discussed below, this method is preferred.
[0034] Fig. 3d to 3f show a more realistic temperature distribution of an EUV mirror as
used in the projection lens 20 (Fig. 1). In Fig. 3d a mirror M
k with its dimensions is shown from the top. For the simulation of the temperature
distribution of this mirror and also the respective aberration a EUV-projection lens
with 6 mirrors (k=1 to 6) was used, as it is shown in Fig, 6. The results for mirror
24 (see Fig. 6) or M
4 are shown in Fig. 3d to 3f which is the fourth mirror after the reticle, counted
in the direction of the projection beam. The EUV-lens with the 6 mirrors is shown
and explained below. In Fig. 3d the temperature distribution is shown with a grey
shading pattern. The temperature increases from the mirror periphery from 22°C which
is the reference temperature T
Ref, up to about T
Ref + ΔT
max(x) = 24°C in the middle black spot. Fig. 3e shows the temperature difference to the
reference temperature as a temperature profile ΔT(x) of the mirror along the x-direction
trough the temperature maximum ΔT
max. Fig. 3f shows the temperature difference to the reference temperature as a temperature
profile ΔT(y) of the mirror along the y-direction through the maximum temperature
ΔT
max. The inhomogeneous temperature profile of the mirror results in deformations of the
mirror surface as explained above. These deformations result in aberrations which
cause image errors or defects. This is shown in Fig. 3g in which the values of the
Zernike-coefficients for the mirror M
4 are given. These coefficients are a quantity or measure for the deviation of an ideal
spherical wavefront in the image plane which generate an image point IP (see Fig.
1).
[0035] To get the Zernike-coefficients a wavefront is expanded in a series of Zernike functions.
An ideal spherical wave has just a first Zernike coefficient and all other coefficients
are zero. So the values of the Zernike-coefficients higher than 2 are a measure for
various imaging errors, and the lager these coefficients are the larger is the optical
aberration of the optical imaging system.
[0036] In Fig. 3g for each Zernike coefficient two values are given. The left value (bar)
is the value without additional heating of the mirror. The right value, given by the
right bar, is the value with an additional homogenous heating of the mirror. This
is now explained in more detail. The mirror M
4 in this example has a mirror body made of ULE® with a zero cross temperature of 25°C.
The reference temperature is T
Ref = 22°C. This means that without EUV light the temperature of the mirror is at 22°C.
Preferably the aberration is minimized at this temperature. If the EUV light is switched
on to project an object point OP to an image point IP then the mirror heats up and
aberration occurs as shown by the respective left bars in Fig. 3g. If the mirror M
4 is additionally homogenously heated by 2°C to be at 24°C before the EUV light is
switched on then the aberration after switching on the EUV light results in the right
bars which are significantly lower than the left ones. This means that the aberration
of the EUV lens can be significantly reduced by the homogenous heating of at least
one lens mirror.
[0037] Fig. 3h to 3l show a further realistic temperature distribution of an EUV mirror
as used in the projection lens 20 (Fig. 1). In Fig. 3h the mirror M
6 of the EUV projection lens of Fig. 6 is shown similar to Fig, 3d. For the simulation
of the temperature distribution of this mirror and also the respective aberration
the EUV-projection lens with the 6 mirrors was used as for Fig. 3d to 3g and as shown
in Fig. 6. The results are shown in Fig. 3h to 3l for mirror 26 (see Fig. 6) or M
6, meaning the sixth mirror after the reticle, counted in the direction of the projection
beam. The temperature increases from the mirror periphery from 22°C, which is the
reference temperature T
Ref, up to about 1.2°C in the middle of the left and right black spots. Fig. 3i shows
the temperature profile along the x-direction of the mirror trough the temperature
maximums where the temperature difference ΔT(x) = T(x) - T
Ref to the reference temperature is given. Fig. 3k shows the temperature difference to
the reference temperature ΔT(y) = T(y) - T
Ref in the y-direction through the minimum temperature between the maxima in x-direction.
The inhomogeneous temperature profile of the mirror results again in deformations
of the mirror surface. The values for the Zernike-coefficients for this mirror are
given in Fig. 3l. The left value (bar) again is the value without additional heating
of the mirror. The right value is the value with an additional heating of the mirror.
The mirror M
6 also has a mirror body made of ULE® with a zero cross temperature of 25°C. The reference
temperature is also T
Ref = 22°C. This means again that without EUV light the temperature of the mirror is
at 22°C. Preferably the aberration is minimized at this temperature. If the EUV light
is switched on to e.g. project an object point OP to an image point IP then the mirror
heats up and aberration occurs as shown by the respective left bars in Fig. 3l. If
the mirror M
6 is additionally homogenously heated up by 3.8°C from the reference temperature T
Ref to be at 25.8°C before the EUV light is switched on, then the aberration, after switching
on the EUV light, results in the right bars which are significantly lower than the
left ones. This means again that the aberration of the EUV lens can be significantly
reduced by the homogenous heating of at least one lens mirror of the projection lens.
[0038] With reference to Fig. 4 a more detailed description of the mirror with the mirror
mounting and the meaning of the reference temperature T
Ref is given. The projection lens 20 as described above with reference to Fig. 1 or Fig.
6 comprises mirrors 21, 22, 23, 24 (25, 26) or in general a plurality of reflective
optical elements M
i, each comprising a body MB
i and a reflective surface MS
i to project at least one object point OP of an object field on a reticle or on a structured
object M onto an image point IP in an image field on a substrate or wafer W if the
projection lens 20 is exposed with an exposure power of EUV light with a wavelength
in a wavelength range less than 50 nm. Preferably a wavelength of about 13 nm is used.
The EUV light is reflected from the reticle M after its illumination by an illumination
system 10 of an EUV-lithographic projection exposure system 100. Further, the projection
lens 20 comprises a support structure for passively or actively supporting the reflective
optical elements M
i (e.g. mirrors 21, 22, 23, 24). The temperature of the support structure or of at
least a part of the support structure is at a reference temperature T
Ref. This is shown in more detail in Fig. 4 which schematically shows a mirror mounting
assembly 400 for the mirror 421, representing one reflective optical element M
k from the plurality of the reflective optical elements M
i which are used in an EUV-lithographic projection exposure system 100 (Fig. 1), and
as described e.g. in
WO 2005/026801 A2. The mirror 421 comprises a mirror body MB
k made of Zerodur® or ULE®, or made of a material comprising e.g. one of the materials
Zerodur® or ULE®, or made of a material having at least one zero cross temperature.
The mirror 421 also comprises a reflective surface 450 with an optional multilayer
of predetermined layer materials with predetermined layer thicknesses to improve the
reflectivity of the projection beam 4 (Fig. 1) of EUV light. The mirror body MB
k is supported by a support element 480. As an example, the mirror 421 is supported
or suspended by three mounting or linking points 451, 452, 453. At each of these mounting
points the mirror body MB
k is connected with linking elements 471, 472, 473 with a bipod structure 461, 462,
463 to achieve a kinematic mount which holds the mirror 421 such that almost no parasitic
forces and/or moments are transferred from the support element 480 to the mirror.
Usually but not necessarily at least one of these bipod structures may comprise an
actuation device. The support element 480 is fixed at a housing structure 481 of the
projection lens 20. The housing structure is sometimes also called projection optical
box or POB. In accordance with the present invention, as a support structure with
a defined or controlled reference temperature T
Ref one of the following elements is preferably selected: The linking points 451, 452,
453, the linking elements 471, 472, 473, the bipod structures 461, 462, 463, the support
element 480 or the housing structure 481. The selected support structure depends among
other things also on the temperature control system which is used in the EUV lithographic
exposure system. For this reason in Fig. 4 all these elements are designated with
T
Ref which does not necessarily mean that all these elements have the same temperature
during the operation of the projection system 100.
[0039] According to the present invention the reference temperature T
Ref is the temperature of the selected support element which supports the reflective
optical element 421 in an operation mode of the EUV lithographic exposure system in
which the EUV light is switched off, or in an operation mode in which the power of
the EUV light is less than about 10% of the exposure power which is usually used for
the projection of the object field on a reticle onto an the image field on the substrate
in an mass production operation mode of the EUV lithographic exposure system. This
reference temperature T
Ref is usually selected close to the room temperature of the clean room in which the
projection lens 20 is operated, meaning that the reference temperature is in the range
of about 20°C to 24°C, preferably 22°C. In most EUV lithographic projection exposure
systems an additional temperature control system controls the reference temperature
T
Ref such that this temperature is constant also during the operation of the projection
lens 20. Usually this is the temperature of the housing structure 481 and/or the support
element 480 (Fig. 4), being e.g. at 22°C as it was chosen in Figures 3. According
to this invention, preferably the temperatures are selected such that the zero cross
temperature T
0k is higher than the reference temperature. This has the advantage that the mirrors
or reflective optical elements have not to be cooled to a temperature below the reference
temperature T
Ref to operate the mirror nearby the zero cross temperature. To avoid the cooling of
the mirrors in an EUV projection lens is an advantage because the lens is operated
in vacuum in which a cooling of the mirrors is technically difficult or expensive.
[0040] Further, in accordance to the present invention the projection lens 20 comprises
a heater 300 to heat at least one optical element M
k, and it comprises a temperature control system 200 to control the temperature of
the at least one optical element M
k to a temperature T
k as shown in Fig. 5 in which like references designate the same or similar parts as
in Fig. 4. On the heatable optical element M
k a spatial temperature distribution ΔT(x,y,z) = (T(x,y,z)-T
Ref) relative to the reference temperature is formed out when the projection lens is
exposed with the exposure power and if the heater 300 is not activated or heated.
This distribution has an average temperature ΔT
av as defined above.
[0041] The at last one heated optical element M
k may be connected to a support structure in the same way as shown in Fig. 4. In addition
the mirror body MB
k of the at least one heated reflective optical element M
k comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a temperature T
0k (this temperature is also called zero cross temperature) which is higher than the
reference temperature T
Ref. Due to the preferred reference temperature of T
Ref = 22°C the preferred zero cross temperature T
0k is between 22°C and about 70°C. As already mentioned such materials are e.g. Zerodur®
or ULE®. The relation of the temperature T
k of the at least one temperature controlled or heatable optical element M
k to the zero cross temperature T
0k and to the reference temperature T
Ref is such that T
k is selected from the group consisting of T
k = T
0k- ΔT
av ; T
k =2
∗T
0k - T
Ref - ΔT
av; T
k =T
Ref + 3
∗(T
0k - T
Ref)/2 -ΔT
av; T
k = T
0k- ΔT
max; T
k = 2
∗T
0k - T
Ref - ΔT
max; Tk = T
Ref + 3
∗(T
0k - T
Ref)/2 -ΔT
max. This temperature T
k preferably is achieved before the formation of the temperature distribution ΔT(x,y,z)
on the optical element M
k, whereas the temperature distribution results from the heating when the optical element
is subjected to the EUV light during the operation mode of the projection system.
This has the advantage that the reflective element M
k is such close to the zero cross temperature that the EUV light of the projection
beam which is absorbed by the mirror or reflective element M
k will heat it up to about the zero cross temperature. The advantage of the invention
is that the zero cross temperature can be selected quite free, since the application
of the heater 300 allows that the mirror can be operated at the favorable zero cross
temperature during the projection process. As an alternative, if ΔT
av is small like about 1K than T
k can also be the zero cross temperature To.
[0042] This means that the temperature T
k is controlled by the temperature control system 200 to such a temperature with the
heater 300 (see Fig. 5). Preferably the heater heats the mirror M
k homogenously to such a constant temperature value. The temperature T
k is the operation temperature of the mirror M
k in an operation mode of the EUV lithographic exposure system in which the power of
the EUV light off. Switching the power of the EUV light to an exposure power which
is usually used for the projection of the object field on a reticle onto an the image
field on the substrate in an mass production operation mode of the lithographic exposure
system then the temperature of the reflective optical element or mirror M
k is increasing by the average temperature ΔT
av to or close to the zero cross temperature T
0. As mentioned, preferably the temperature T
k is already controlled to its value before the EUV light is switched on. In a preferred
embodiment the heater is controlled such that the thermal energy to which the mirror
M
k is subjected is constant. This means that if e.g. the mirror absorbs some other energy,
e.g. some EUV light, then the heater reduces its heating power such that the total
input of thermal energy onto the mirror is constant in time. This results in that
the average temperature of the mirror is also constant or almost constant in time.
A more detailed description of the various preferred values of T
k will be given below.
[0043] The temperature T
k may be controlled at the reflective surface MS
k or at the mirror body MB
k. The above given relations between the temperatures T
0k (the zero cross temperature), the operation temperature T
k of mirror M
k (or in general the reflective optical element) and the reference temperature T
Ref of the support structure as well as the average temperature ΔT
av result in very small length variations or surface figure variations of the reflective
optical element M
k for most practical cases, and the aberration or image errors are significantly reduced,
as shown in Fig. 3g and 3l, in which the temperature T
k is controlled to about T
k = T
0k- ΔT
av and T
k=T
Ref + 3
∗(T
0k - T
Ref)/2 -ΔT
av.
[0044] The equation T
k =T
Ref + 3
∗(T
0k - T
Ref)/2 -ΔT
av is also considering that there is also a temperature distribution in the thickness-
or z-direction of the mirror and not only on the surface of the mirror. If it is assumed
that on the side of the reflective surface there is the temperature T
k, e.g. at the periphery of the mirror, and if at the backside of the mirror there
is the reference temperature T
Ref due to any thermal conduction e.g. of the support structure which is at this temperature,
then a good temperature for T
k is given by T
k =2
∗T
0k-T
Ref - ΔT
av. However, the accuracy of the temperature control system or the accuracy with which
the temperature T
k is controllable will also influence the aberration or imaging errors. If the accuracy
of the temperature of the body MB
k of the reflective optical element M
k is within□ ± 1K due to the temperature control and other system variations then the
relative change of the length is normally less than about 10 ppb as it can be schematically
seen by reference numeral 303 in Fig. 3c. However, this assumes that the operation
temperature can be chosen between about T
Ref + (T
0k - T
Ref )/2 and T
Ref + 3
∗(T
0k - T
Ref)/2. As it can be seen from Fig. 3c, if the operation temperature is too close to
the reference temperature T
Ref, or in general too far from the zero cross temperature T
0k, then the relative change of the length is much more than 10 ppb as shown by the
reference numerals 304 and 305. In such cases there is significant risk of mirror
deformation due to deformation of the body MB
k, resulting in a deterioration of the optical performance of the system. For these
reason the operation temperatures T
k = T
0k- ΔT
av and T
k = T
Ref + 3
∗(T
0k - T
Ref)/2 -ΔT
av are preferred, especially if they are within the interval [T
Ref + T
0)/2; T
Ref + 3
∗(T
0k-T
Ref)/2].
[0045] Further it is advantageous to select a material such that the zero cross temperature
of the material for the mirror body MB
k is higher than according to any design calculations or simulations which are used
for the design of the projection lens. In these calculations any fluctuations of the
surrounding temperature, variations in design assumptions for the lens design, the
EUV light source and also the variations of reticle reflections may be considered
which results in the calculation of the maximum or average temperature of the mirror
M
k when the EUV projection lens is designed. If the zero cross temperature is selected
several Kelvin higher than the calculated values then the EUV lens can be operated
under all conditions at the preferred temperature close to the zero cross temperature
at which the aberration is minimized. This operation temperature of the mirror may
be achieved by a homogenous and controlled heating with the heater 300 and the controller
200. For the heater 300 various embodiments can be used. Examples are heating elements
formed out as metal plates and arranged closed to the mirror, preferably close to
the backside of the mirror. Such plates are electrically heated. Alternative or in
addition electrical heating elements are in direct contact with the mirror body. A
further alternative or additional heater comprises an infrared source with which the
mirror or reflective element is illuminated.
[0046] Further, the temperature control system 200 may comprise a sensor which directly
measures the mirror temperature T
k at one or several positions. In further embodiments of the invention the temperature
T
k of the at least one optical element M
k which is controlled by the temperature control system can be a temperature T
MSk of the reflective surface MS
k (Fig. 5) of the optical element M
k or a temperature T
MBk of the body MB
k of the optical element M
k. Alternative T
k can be a temperature given by a function of the temperature T
MBk of the body MB
k and/or the temperature of the reflective surface MS
k. Further, the temperature of the reflective surface T
MSk can be an average surface temperature. Such averaging can e.g. be done by measuring
the surface temperature with an infrared camera or by a space-resolving pyrometer.
Also the temperature of the body T
MBk can be an average temperature of a plurality of temperatures measured at a plurality
of spatial positions at the body MB
k. Preferably the spatial positions or a subset of the spatial positions at which the
temperature of the mirror body is measured is arranged close to the reflective surface.
By the controller 200 a temperature value or control parameter can be calculated from
the measurements of the temperature or the temperatures of the reflective surface
and/or the body. As a further alternative, as mentioned above, the temperature T
k for the control system is selected from a spatial temperature distribution of the
body MB
k or the reflective surface T
MSk. Depending on whether the temperature of the optical element M
k is measured at one or several locations and whether the temperature control system
comprises one or more input channels for the temperature signals, one of the mentioned
temperature control option is selected. As an alternative or in addition, the optical
aberration can be determined and the temperature controller 200 controls the mirror
temperature such that the aberration becomes a minimum. For the temperature control
or the control of the aberration the temperature T
k not necessarily explicitly has to be determined. Also a model based controller can
be used the control the temperature of the mirror or the heat of the heater which
is transferred to the mirror. The model may consider parameters like the power of
EUV light to which the lens is exposed, illumination settings with which a reticle
is illuminated, the structures on the reticle and the optical aberration of the lens.
[0047] In a further embodiment the EUV light of the illuminated reticle comprises a spatial
distribution of angular, polarization and intensity in accordance with an illumination
setting. This usually results in a spatial temperature distribution ΔT(x,y,z) = (T(x,y,z)-T
Ref) relative to the reference temperature T
Ref. This temperature distribution usually has an average temperature ΔT
kav and a maximum temperature ΔT
kmax= (T
Ref + ΔT
kmax). It should be mentioned that this temperature distribution is formed out on the
reflective surface MS
k of the heatable optical element M
k when the projection lens is exposed with the exposure power without heating the heater.
[0048] As an alternative to the above described selections of the temperature T
k, the temperature T
k is selected as T
k = (T
0k + T
Ref + ΔT
kmax)/2 after the determination of the temperature distribution. Depending on ΔT
kmax this selection has the advantage that the heated optical element is heated closer
to the zero cross temperature in cases if the zero cross temperature is higher than
the maximum temperature T
kmax.= T
Ref + ΔT
kmax As mentioned above T
k may be the temperature T
MBk of the body MB
k of the optical element M
k, the temperature given by a function of the temperature T
MBk of the body MB
k and the temperature T
MSk of the reflective surface MS
k or the temperature selected from a spatial temperature distribution of the body MB
k or the reflective surface T
MSk, before the power of the EUV light of the projection beam 4 is switched on.
[0049] In a further embodiment of the projection lens in accordance with this invention
the temperature T
k of the optical element M
k is controlled to its value by heating the heater with a first heating power at a
time before the projection lens is subjected to the exposure power of the EUV light.
This has the advantage that the operation temperature of the optical element T
k before the exposure with EUV light is very close to the operation temperature during
the exposure. This results in that the changes of aberration errors as a function
of exposure time can be significantly reduced and the projection system is much quicker
in a steady state working condition in which the imaging quality will almost not change.
Preferably during exposure (during the time subjecting the projection lens to the
exposure power of the EUV light) the heating power of the heater is less than the
first heating power. This is to prevent a warming up of the optical element M
k.
[0050] In a further embodiment of the projection lens according to this invention a second
heater for the heating of a second optical element M
2k to a temperature T
2k is used, wherein the body MB
2k of the second optical element M
2k also comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a temperature T
02k higher than the reference temperature. On the second optical element a second spatial
temperature distribution ΔT
2(x,y,z) = (T
2(x,y,z)-T
Ref) relative to the reference temperature T
Ref is formed out when the projection lens is exposed with the exposure power without
heating the second heater, having an average temperature ΔT
2av and a maximum temperature ΔT
2max. Analogous to the embodiment described above, also in connection with Fig. 3c, the
temperature T
2k of the second optical element M
2k is selected according to the same relations as described above for the operation
temperature T
k of the first heated mirror M
k. This means that the operation temperature T
2k of the second optical element M
2k is preferably selected from the group consisting of : T
2k = T
02k -ΔT
2av; T
2k =2
∗T
02k - T
Ref - ΔT
2av; T
2k =T
Ref + 3
∗(T
02k - T
Ref)/2 -ΔT
2av; T
2k = T
02k- ΔT
2max; T
2k= 2
∗T
02k - T
Ref - ΔT
2max; T
2k = T
Ref + 3
∗(T
02k - T
Ref)/2 -ΔT
2max. Then the optical element or mirror M
2k is, or preferably is heated to such a temperature T
2k before the power of the EUV light of the projection beam 4 is switched on. In this
embodiment the material of the body MB
2k may be the same or different from the material of the body MB
k of the first optical element. In the first case of the same material, preferably
the material has a different zero cross temperature than for the first reflective
element M
k may be selected such that the CTE(T)-function (see e.g. Fig. 2b) has different algebraic
signs for the slopes at the respective zero cross temperatures. This requires that
the material comprises at least two zero cross temperatures T
0 and T
02, as shown in Fig. 2b for a Zerodur® material. An example for different materials
is the usage of ULE® for one optical element and Zerodur® for the other. Also in this
case preferably the algebraic signs for the slopes at the respective zero cross temperatures
are different. This advantageously can be used as a further measure to reduce aberration,
as is described e.g. in
WO 2005/040924 A1.
[0051] Fig. 6 shows an additional schematic arrangement of an EUV-projection lens which
comprise 6 mirrors as reflective optical elements M
1 to M
6 which are respectively designated with reference numerals 21, 22, 23, 24, 25 and
26. In Fig. 6 like references designate the same or similar parts as in Fig. 1. Further,
the mirrors are numbered as they are arranged in the downstream direction of the projection
beam 4 which goes from the reticle M to the wafer W. If such a EUV projection lens
20 as shown e.g. in Fig. 1 or Fig. 6 is exposed with EUV light to project an object
point OP to an image point IP on the wafer W then the individual mirrors are warmed
up. Preferably, before the EUV light is switched on, these mirrors are at the reference
temperature T
Ref of e.g. 22°C. Fig. 7 shows an example for a warming of the six mirror of the projection
lens 20 of Fig. 6, if such a lens is exposed with a projection beam 4 which has a
power of 16 W after the reticle M. For the generation of this power a light source
power of more than 1kW is necessary for the light source 1 (see Fig. 1). The shown
diagram is a simulation calculation in which the reticle is illuminated with a dipole
illumination setting which gives a temperature distribution on the last mirror M
6 similar as shown in Fig. 3h. The dipole can be seen on the mirror, since this mirror
is arranged nearby or at a pupil plane of the projection lens 20.
[0052] In Fig. 7 for each of the 6 mirrors the average temperature ΔT
av , which is the respective lower curve, is shown as a function of time. The average
temperatures are calculated as defined above. Also for each mirror the maximum temperature
ΔT
max of the temperature distribution ΔT(x,y,z) is shown as a function of time which is
represented by the respective upper curve for each mirror. It can be seen that the
thermal load for the mirrors M
5, M
3 and M
2 is such that these mirrors warm up of about 4.5K, 4.0K and 3.5K respectively. M
1 warms up of about 2K and M
4, M
6 warm up of about 0.5K. Further, it can be seen that the mirrors need about 150 minutes
or more to reach an almost constant steady state temperature. During this time the
effective position of the reflective surfaces and the surface figures of these surfaces
will change, as explained with Fig. 3a to 3c. This results in optical aberration as
described above, since the average temperatures are changing in time relative to the
respective zero cross temperatures. However, the lens 20 may be optimized for the
steady state condition. This means that the zero cross temperature for the mirrors
is selected such that it is the steady state temperature or almost the steady state
temperature, meaning T
0i = (T
av i + T
Ref) for the i-th mirror (i = 1 to 6). In this case the aberration is minimized as described
in connection with Fig. 3a to 3c. If the mirror is fabricated regarding its surface
figure at a temperature of about 22°C (or in general at or close to a reference temperature)
then this surface figure remains almost the same even if the mirror is homogenously
heated to the such selected zero cross temperature as it was explained in connection
with Fig. 3a. Further, if the mirror has a spatial temperature distribution T(x,y,z)
due to the absorbed power of the projection beam 4 then the aberration generated by
this absorption is also minimized as explained in Fig. 3b and 3c. Practically the
suggested optimization (by material selection) of the zero cross temperatures has
the following drawbacks:
- 1. The steady state temperature depends on the power of the light source, on the illuminated
reticle and the used illumination setting with which the reticle is illuminated.
- 2. The manufacturing of the mirror material with a specified zero cross temperature
is very expensive. In addition, there are manufacturing tolerances such that the specified
zero cross temperature only can be achieved by selecting out the required material
from a larger set of materials, having the manufacturing tolerances. This would be
extremely expensive. In US 2003/0125184 A1 the difficulties of the production of Zerodur® with certain predefined zero cross
temperatures are described. Further, also the difficulties concerning the determination
of the zero cross temperature is shown.
- 3. There will be unacceptable aberration during the warm up phase within the about
first 2 to 3 hours in which the EUV-lens could not be used for mass production of
micro-structured objects.
[0053] The influence of the above drawbacks on aberration can be seen in Fig. 8. Fig. 8
shows the aberration in form of the Zernike-coefficient Z5. For Z5 its RMS (root mean
square) value is given for each of the 6 mirrors of the lens which is shown in Fig.
6. Z5 is shown as a function of the zero cross temperature if each mirror of the projection
lens is in the steady state as described in Fig. 7. The bars for each mirror show
how the aberration increases if the zero cross temperature is selected higher or lower.
The calculations were done in 1K steps for zero cross temperatures from 18°C (left
most bar) to 34°C (right most bar). For M
2, which has a steady state temperature of about 25.5°C (T
av 2 = 3.5K with T
Ref = 22°C), the aberration values for various zero cross temperatures are shown e.g.
by the shown arrows with the respective zero cross temperature data. The best zero
cross temperature in accordance to Fig. 8 should be between 26°C and 27°C which is
in good agreement that lowest aberration should be achieved if the steady state temperature
(25.5°C) corresponds to the zero cross temperature. Fig. 8 clearly shows that if the
steady state temperature of a mirror doses not match with the zero cross temperature
within about ±1K then the aberration will increase. Since the steady state temperature
T
Ref + ΔT
av depends on the power of the EUV light source, on the used illumination setting, the
used reticle and some other aspects, it seems impossible to construct an EUV-lens
such that under all the mentioned working conditions the aberration can be brought
to a minimum, since if the mirror materials are selected then the zero cross temperatures
are fixed.
[0054] Also in Fig. 8 the influence of the manufacturing tolerances regarding the zero cross
temperatures T
0k can be seen. If e.g. for mirror M
2 a zero cross temperature of 27°C would minimize aberration, and if the produced material
has a zero cross temperature T
02 = 29°C this will almost double the aberration. For mirror M
1 a deviation of 2K from the best zero cross temperature will result in even higher
aberrations, as shown with the arrows 81 and 82.
[0055] Fig. 9 shows the optimized zero cross temperature as a function of the EUV light
power P after the reticle M to which the EUV lens 20 is subjected during projection.
The calculation is done for settings which produce the largest aberrations. It can
be seen that the optimized zero cross temperature T
0i for all mirrors increase in good approximation linearly with power P. The calculation
was done up to 16W and ULE® was chosen as mirror material for all 6 mirrors as for
the calculations of Fig. 7 and Fig. 8. Further, it can be seen that the variation
of the zero cross temperatures within one EUV lens also increases with power, if the
manufactured lens 20 shall be optimized regarding optical aberration. This means that
different materials have to be used for the production of the mirrors, having different
zero cross temperatures with a broad variation. This makes the manufacturing also
very expensive. Further, the inventors realize for the first time that for higher
exposure powers the zero cross temperatures within a projection lens must differ more
than 6K, even more than 8K, if the EUV lens is optimized to the EUV light power and
aberration. For this reason preferably in a further embodiment of the above described
embodiments of the inventive projection lens the absolute value of the difference
between the zero cross temperatures T
0k, T
02k of the heatable optical element and the second heatable optical element is selected
such that it is more than 6K, expresses as abs(T
0k - T
02k)> 6K. With such a projection lens advantageously the optical aberration (caused by
thermal effects due to absorption of EUV light at the optical elements) can be reduced
even at higher EUV light powers. In a further embodiment of the above described inventive
projection lenses the zero cross temperature T
0k of the at least one heatable optical element M
k is higher than the maximum of the highest reference temperature T
Ref and the average or maximum temperature ΔT
av + T
Ref or ΔT
max + T
Ref, based on the respective spatial temperature distribution ΔT(x,y,z), expressed as
T
0k > max(T
Ref, ΔT
av + T
Ref) or T
0k > max(T
Ref, ΔT
max + T
Ref). This has the advantage that with the heater 300 the at least one heatable optical
element can be heated up to the zero cross temperature independently of the EUV light
power (and the reference temperature) used during the projection process. Such the
optical aberration can be minimized for all operation conditions of the projection
lens 20. The teaching of the inventive embodiments described above is independent
of the number of mirrors. It can be applied e.g. to a projection lens 20 as shown
in Fig. 1, having 4 mirrors 21, 22, 23 and 24, or to a projection lens 20 as shown
in Fig. 6, comprising 6 mirrors 21, 22, 23, 24, 25 and 26.
[0056] Further, to minimize the optical aberration especially in projection lenses 20 in
which at least one mirror or optical element M
k is heated by a heater 300, it is advantageous to connect the at least one heated
optical element M
k to an actuator for its translational movement. This allows to shift the mirror M
k to compensate a homogeneous heating of the mirror M
k as it was described in connection with Fig. 3a. Further, the heater 300 for heating
the mirror or optical element M
k advantageously comprises heating elements selected from the group consisting of IR
light emitting diodes, Peltier elements, optical fibers, light guide rods and IR lasers,
as will be described in more detail below with the description of Fig. 13. Further,
such heating elements are optionally arranged in one dimension or in two dimensions
at predefined spatial coordinates, forming a grid structure. Advantageously in the
embodiments in which the heating elements are emitting or guiding IR radiation, these
embodiments comprise an optical arrangement to configure the IR radiation, the optical
arrangement comprises arrangement elements selected from the group consisting of collimator,
focusing lens, adjustable lens, mirror and diffractive optical element, wherein the
arrangement elements may be tiltable around at least on axis. Examples of such optical
arrangements are shown in Fig. 13.
[0057] Further, in an alternative embodiment of the above described projection lenses the
at least one optical element M
k comprises a modification in or on the mirror body MB
k. The modification is selected from the group consisting of recess, blind hole, defined
surface roughness, diffractive structure, spherical protrusion, spherical recess and
surface curvature. The modification, which is described in more detail below in connection
with Fig. 13, advantageously is used to guide e.g. IR radiation to heat the optical
element locally.
[0058] Due to the above finding that for higher exposure powers the zero cross temperatures
of the mirrors within a projection lens must differ by 6K or more, the present invention
also relates to a further, projection lens, in the following called
first projection lens, which is designed to be exposed with an exposure power of more than 8W of EUV light
with a wavelength in a wavelength range of less than 50 nm, preferably with a wavelength
of 13 nm. The calculations for Fig. 7, Fig. 8 and Fig. 9 were done with 13 nm and
for a lens 20 with 6 mirrors, as shown in Fig. 6. Generally such a lens comprises
at least two reflective optical elements M
i like mirrors. Each mirror or reflective optical element comprises a body MB
i and a reflective surface MS
i to project an object field on a reticle onto an image field on a substrate if the
projection lens is exposed with the exposure power of the EUV light. This light is
reflected from the reticle after the reticle is illuminated by an illumination system
of an EUV-lithographic projection exposure system. Further, the bodies MB
m, MB
n of at least two reflective optical elements comprise a material with a temperature
dependent coefficient of thermal expansion which is zero at respective zero cross
temperatures Tom, Ton , wherein the absolute value of the difference between the zero
cross temperatures Tom, Ton in this first projection lens is more than 6K, expresses
as abs(Tom - Ton)> 6K. This is e.g. the case for mirror M
5 and mirrors M
4 or M
6 if the lens is subjected an exposure power of 8W or more, as can be seen from Fig.
8.
[0059] As a further second embodiment of such a first projection lens the lens can comprise
four or six reflective optical elements M
i or mirrors (as e.g. shown in Fig. 1 and in Fig. 6) and preferably the projection
lens is designed to be exposed with an exposure power of more than 10W. In this case
the absolute value of the difference between the zero cross temperatures Tom, Ton
is more than 8K, expresses as abs(T
0m - T
0n)> 8K. For the 6-mirror lens 20 of Fig. 6, Fig. 9 clearly shows this for the mirrors
M
5 and M
4 or M
6. The zero cross temperatures of these mirrors differ by more than 8 K if the exposure
power goes above 10 W.
[0060] The first projection lens and its previous embodiments in a third embodiment may
comprise a support structure for passively or actively supporting the reflective optical
elements M
i, as it was described in connection with Fig. 4 and Fig. 5. The temperature of at
least a part of the support structure is at a reference temperature T
Ref, which is e.g. selected as 22°C. Further, the lens in accordance with an embodiment
of the first lens comprises a heater 300 for heating at least one of the mirror bodies
MB
n, MB
m which comprise the materials with the different zero cross temperatures. A temperature
control system 200 controls the temperature of the at least one heated mirror body
MB
n, MB
m to a temperature T
k. Preferably the heater 300 is made such that the body can be homogenously heated.
This means that the body MB
n, MB
m is homogenously heated in at least one dimension of the body. Various types of heaters
300 will be described below in this description.
[0061] In an further fourth embodiment of the first lens (and its previous embodiments),
there, without the operation of the just mentioned heater 300, the exposure of the
reflective surfaces MS
m and MS
n of the bodies MB
n, MB
m with EUV light, results in temperature distributions ΔT
n(x,y,z) = (T
n(x,y,z)-T
Ref), ΔT
m(x,y,z) = (T
m(x,y,z)-T
Ref) of the bodies MB
n, MB
m relative to the reference temperature T
Ref with respective average and maximum temperatures ΔT
nav, ΔT
mav and ΔT
nmax and ΔT
mmax. The EUV light with which the reflective surfaces MS
m and MS
n are exposed is reflected by the illuminated reticle and comprises a spatial distribution
of angular, polarization and intensity parameters in accordance with an illumination
setting. In this embodiment at least one zero cross temperatures T
0m, T
0n is selected higher than the maximum of the highest reference temperature T
Ref and the respective average or maximum temperature ΔT
mav + T
ref or ΔT
mmax + T
ref, ΔT
nav + T
ref or ΔT
nmax + T
ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z), expressed as T
0m > max(T
Ref, ΔT
mav + T
ref), T
0m > max(T
Ref, ΔT
mmax + T
ref) or T
0n > max(T
Ref, ΔT
nav + T
Ref), T
0n > max(T
Ref, ΔT
nmax + T
ref).
[0062] Usually the reference temperature is constant and is chosen as the temperature of
the support element 480 or the housing structure 481 (see Fig. 4 and 5). Often the
backside of the mirror also has this temperature even if the lens is subjected to
the exposure power of the EUV light. The advantage of this selection of the zero cross
temperature is that with the usage of the heater 300 the respective mirror always
can be brought to the zero cross temperature by heating. This is because usually,
without the application of the heater 300, the mirror only heats to an average temperature
as explained with Fig. 7. If the zero cross temperature is adapted to this temperature
then the optical aberration becomes minimal, as it was described in connection with
Fig. 3a and Fig. 3b. However, if the zero cross temperature is selected higher than
the absolute average temperature T
Ref + ΔT
mav or T
Ref + ΔT
nav then by heating the mirror with the additional heater 300 it can be heated to or
close to the selected zero cross temperature to minimize aberration.
[0063] In a further 5
th embodiment of the first projection lens (and its previous embodiments) also the manufacturing
tolerances of the zero cross temperature is taken into account. This means that if
the materials of the first projection lens according to this invention, which comprises
materials with the zero cross temperatures T
0m, T
0n, vary regarding their real values of the zero cross temperature due to the manufacturing
process, resulting in manufacturing tolerances ΔT
0m, ΔT
0n, then the respective real values are within the temperature intervals T
0m ± ΔT
0m and T
0n ± ΔT
0n. In this case advantageously at least one zero cross temperatures Tom, Ton is selected
higher than the maximum of the highest reference temperature T
Ref and the respective absolute average or maximum temperature ΔT
mav + T
Ref or ΔT
mmax + T
Ref, ΔT
nav + T
Ref or ΔT
nmax + T
Ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z), but in addition, these values are increased by the absolute value of the
respective manufacturing tolerances ΔT
0m, ΔT
0n, expressed as T
0m > max(T
Ref, ΔT
mav + T
Ref) + |ΔT
0m|, T
0m > max(T
Ref, ΔT
mmax + T
Ref) +|ΔT
0m| or T
0n > max(T
Ref, ΔT
nav + T
Ref) +|ΔT
0n|, T
0n > max(T
Ref, ΔT
nmax + T
Ref) +|ΔT
0n|. Such a material selection regarding the zero cross material has the big advantage
that the specification regarding the zero cross temperature can be relaxed, because
the heater 300 guaranties that the respective heatable reflective optical element
with the selected zero cross temperature can be heated to or close to the zero cross
temperature by additional heating and such the aberration can be minimized. Preferably
but not necessarily, the heating is done such that the mirror is homogenously heated.
This simplification regarding the material selection results in enormous cost savings.
If the maximum temperatures ΔT
nmax and ΔT
mmax instead of the average temperatures ΔT
nav, ΔT
mav are chosen for the election of the zero cross temperature, then in the selection
process the system is more robust, e.g. regarding changes in exposure powers to higher
values.
[0064] In a further 6
th preferred embodiment of the first lens (and its previous embodiments) the temperature
of the heated mirror bodies or the heated mirror body MB
n, MB
m is controlled to values of the temperature T
k which are within an interval of ± 5K, better ± 2K centered around the respective
zero cross temperature T
0m, T
0n to minimize any thermal induced optical aberration.
[0065] The above mentioned item 3 of the drawbacks that the system cannot be used in the
warm-up phase if the zero cross temperatures are optimized to the steady state, as
e.g. shown in Fig. 7, can be solved by the 3
rd to 6
th embodiments of the first EUV lens of this invention, due to the usage of the heater
300. To also solve this drawback, in a 7
th embodiment of the first lens in accordance to one of its 3rd to 6
th embodiments the projection lens 20 is heated at a time before the projection lens
is exposed with the exposure power of the EUV light. There the temperature T
k of the at least one heated body MB
n, MB
m of the reflective optical elements M
n, M
m is controlled to its value by heating the heater 300 with a first heating power.
Preferably the temperature T
k is selected from the values of the above 3
rd to 6
th embodiment of the first projection lens. Depending on the values of the zero cross
temperatures and the power of the exposure light to which the EUV lens is subjected,
in a 8
th embodiment of the first lens the heating power of the heater is selected lower than
the first heating power, as mentioned in the 7
th embodiment, during the time of exposure of the projection lens 20 with the exposure
power of the EUV light. In a preferred 9
th embodiment of the first lens the temperature control system 200 controls the temperature
T
k such that the heating power of the heater 300, which heats the at least one body
MB
n, MB
m of the reflective optical elements M
n, M
m, and the exposure power of the EUV light which is absorbed by the at least one heated
body MB
n, MB
m is constant or is almost constant in time. Advantageously this will result in minimal
temperature fluctuations of the mirror body and such the thermal induced optical aberration
is minimized too.
[0066] The first lens and it various embodiments essentially make use of materials for the
reflective optical elements or mirrors which differ significantly regarding its zeros
cross temperature. It shall be mentioned that the present invention of the first lens
and its various embodiments are not limited to EUV projection lenses with 4 or 6 reflective
optical elements in form of mirrors, as described in Fig. 4 and Fig. 6. It is assumed
that the number of mirrors of an EUV projection lens of a lithographic projection
exposure apparatus increases to more than 6 if the EUV power of the EUV exposure light
also increases. The EUV light power will depend on the EUV light sources which will
be available in future. Generally the number of mirrors may vary in accordance to
the requirements, and the principles of the teaching in connection with the first
projection lens may be applied to each mirror or to each reflective optical element,
especially if used in an EUV lithographic projection exposure apparatus.
[0067] Further, to minimize the optical aberration especially in projection lenses 20 according
to the first lens of this invention in which at least one mirror or optical element
M
k is heated by a heater 300, it is advantageous to connect the at least one heated
optical element M
k to an actuator for its translational movement. This allows to shift the mirror M
k to compensate a homogeneous heating of the mirror M
k as it was described in connection with Fig. 3a. Further, the heater 300 for heating
the mirror or optical element M
k advantageously comprises heating elements selected from the group consisting of IR
light emitting diodes, Peltier elements, optical fibers, light guide rods and IR lasers,
as will be described in more detail below with the description of Fig. 13. Further,
such heating elements are optionally arranged in one dimension or in two dimensions
at predefined spatial coordinates, forming a grid structure. Advantageously in the
embodiments in which the heating elements are emitting or guiding IR radiation, these
embodiments comprise an optical arrangement to configure the IR radiation, the optical
arrangement comprises arrangement elements selected from the group consisting of collimator,
focusing lens, adjustable lens, mirror and diffractive optical element, wherein the
arrangement elements may be tiltable around at least on axis. Examples of such optical
arrangements are shown in Fig. 13.
[0068] Further, in an alternative embodiment of the above described first projection lenses
the at least one optical element M
k comprises a modification in or on the mirror body MB
k. The modification is selected from the group consisting of recess, blind hole, defined
surface roughness, diffractive structure, spherical protrusion, spherical recess and
surface curvature. The modification, which is described in more detail below in connection
with Fig. 13, advantageously is used to guide e.g. IR radiation to heat the optical
element locally.
[0069] An alternative embodiment to the first lens is a
second projection lens for an EUV lithographic exposure system which is described below. The inventors'
realized that the usage of a heater 300 will have a significant influence to the lens
design, especially to the material selection requirements for the mirror material.
[0070] A first embodiment of the second projection lens 20 in accordance with this invention
comprises at least two reflective optical elements M
i like mirrors as shown in Fig. 1 and Fig. 6, designated as 21, 22, 23, 24, 25 and
26. Each such element comprises a body MB
i and a reflective surface MS
i for projecting an object field OP on a reticle onto an image field IP on a substrate
if the projection lens 20 is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm. Preferably a wavelength of 13 nm is used.
The EUV light is reflected from the reticle after illumination by an illumination
system of an EUV-lithographic projection exposure system. The bodies MB
m, MB
n of at least two reflective optical elements of the lens 20 comprise a material with
a temperature dependent coefficient of thermal expansion which is zero at respective
zero cross temperatures Tom, Ton , as e.g. shown in Fig. 2a and Fig. 2b. As an example
such materials are Zerodur® or ULE®, but also Superinvar. In addition the second lens
comprises a support structure for passively or actively supporting the reflective
optical elements M
i. Such a support structure was described in detail in connection with Fig. 4 and Fig.
5. The temperature of at least a part of the support structure is at a reference temperature
T
Ref, for example at 22°C as it is in the embodiments of Fig. 3 and Fig.6. This temperature
is close to the temperature of the clean-room. Usually the mirrors or reflective optical
elements of the EUV projection lens are specified regarding their surfaces and surface
figures also at this reference temperature. Further, the second projection lens comprises
a heater 300 for heating at least one of the bodies MB
n, MB
m of the reflective optical elements with the zero cross temperatures. Also the second
lens comprises a temperature control system 200 for controlling the temperature of
the at least one heated body MB
n, MB
m to a temperature T
km,, T
kn. Further, if in the second lens the bodies MB
n, MB
m are not heated with the heater, then the exposure of the reflective surfaces MS
m and MS
n with EUV light, which is reflected by the illuminated reticle, results in temperature
distributions ΔT
n(x,y,z) = (T
n(x,y,z)-T
Ref), ΔT
m(x,y,z) = (T
m(x,y,z)-T
Ref) of the bodies MB
n, MB
m relative to the reference temperature T
Ref with respective average and maximum temperatures ΔT
nav, ΔT
mav and ΔT
nmax and ΔT
mmax. The EUV-light usually comprises a determined spatial distribution of intensity,
angular and polarization parameters which is defined by an illumination setting.
[0071] Further, in the second lens at least one zero cross temperatures Tom, Ton is selected
higher than the maximum of the highest reference temperature T
Ref and the respective absolute average or maximum temperature ΔT
mav+T
Ref or ΔT
mmax+ T
Ref, ΔT
nav+T
Ref or ΔT
nmax + T
Ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z), expressed as T
0m > max(T
Ref, ΔT
mav + T
ref), T
0m > max(T
Ref, ΔT
mmax + T
Ref ) or T
0n > max(T
Ref, ΔT
nav + T
Ref), T
0n > max(T
Ref, ΔT
nmax + T
Ref). If the absolute maximum temperature instead of the absolute average temperature
is considered in the selection process then the system is more robust, e.g. regarding
changes in exposure powers to higher values. The second projection lens according
to this invention selects the material for the mirrors or reflective optical elements
on the basis of the average or maximum temperature which a mirror may achieve if it
is illuminated by the projection beam. Due to the application of a heater, the zero
cross temperature can be reached independent of whether the projection lens is operating
with low or high EUV light power of the projection beam. Preferably the maximum or
average temperatures on the heatable mirror bodies are determined for the maximum
power to which the projection lens may be subjected. For the embodiments of the second
projection lens according to this invention, for the reference temperature the same
can be applied as described in connection with the first projection lens and the description
in connection with Fig. 4 and Fig. 5.
[0072] To consider the manufacturing tolerance of the zero cross temperatures a 2
nd embodiment of the second projection lens considers that the materials with the zero
cross temperatures T
0m, T
0n may vary regarding the values of the zero cross temperatures due to manufacturing.
Usually this results in manufacturing tolerances ΔT
0m, ΔT
0n such that the respective real values of the zero cross temperatures are within the
intervals T
0m ± ΔT
0m and T
0n ± ΔT
0n. If so, it is advantageous to select at least one zero cross temperatures T
0m, T
0n in the second lens higher than the maximum of the highest reference temperature T
Ref and the respective average or maximum temperature increased by the reference temperature,
resulting in ΔT
mav + T
Ref or ΔT
mmax + T
Ref, ΔT
nav + T
Ref or ΔT
nmax + T
Ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z). This maximum is further increased by the absolute value of the respective
manufacturing tolerances ΔT
0m, ΔT
0n, expressed as T
0m > max(T
Ref, ΔT
mav + T
Ref) +|ΔT
0m|, T
0m > max(T
Ref, ΔT
mmax + T
Ref) +|ΔT
0m| or T
0n > max(T
Ref, ΔT
nav + T
Ref) +|ΔT
0n|, T
0n > max(T
Ref, ΔT
nmax + T
Ref) +|ΔT
0n|. Similar like in the first embodiment of the second lens, instead of the absolute
maximum temperatures also the absolute average temperature may be sufficient, but
in this case the second lens will be less robust against a raise of temperature of
the mirrors which may result from higher exposure power.
[0073] In a 3
rd embodiment of the second projection lens the absolute value of the difference between
the zero cross temperatures T
0m, T
0n is more than 6K, expresses as abs(T
0m - T
0n) > 6K. Preferably in this case the second projection lens is designed to be exposed
with an exposure power of more than 8W of EUV light with a wavelength in a wavelength
range of less than 50 nm. As already described in connection with the description
of the first projection lens of this invention the same advantages are also valid.
Preferably the wavelength is in a wavelength interval selected from the group consisting
of [12 nm, 14 nm], [12.5 nm, 13.5 nm], [5 nm, 15 nm], [15 nm, 25 nm] and [25 nm, 50
nm]. Such a selection of the wavelength also could be done for the other embodiments
of the lenses of the EUV lithographic projection exposure systems which are described
in the present specification.
[0074] In a 4
th embodiment of the second projection lens at least four or six reflective optical
elements M
i are used. Further the projection lens is designed to be exposed with an exposure
power of more than 10W of EUV light with a wavelength in a wavelength range of less
than 50 nm. With higher power of the EUV light usually also the number of mirrors
increase. For a power of 16W usually 6 mirrors are used as shown in Fig. 6. The absolute
value of the difference between the zero cross temperatures T
0m, T
0n is more than 8 K in this embodiment, expresses as abs(Tom - Ton)> 8K.
[0075] A 5
th embodiment of the second lens in accordance to this invention controls the temperature
T
k of the at least one heated body MB
n, MB
m within an interval of ± 5K, better ± 2K centered around the respective zero cross
temperature T
0m, T
0n to minimize any thermal induced optical aberration.
[0076] In a 6
th embodiment of the second projection lens at a time before the projection lens is
subjected to the exposure power of the EUV light the temperature T
k of the at least one heated body MB
n, MB
m is controlled to its value by heating the heater 300 with a first heating power.
This is similar to the 7
th embodiment of the first projection lens and reduces the warm-up phase of the EUV-projection
system. Further, in an 7
th embodiment of the second projection lens the heating power of the 6
th embodiment is less than the first heating power when the projection lens is exposed
to the exposure power of the EUV light. In a more advanced 8
th embodiment of the second projection lens the temperature control system 200 controls
the temperature T
k such that the heating power of the heater 300, which heats the at least one body
MB
n, MB
m, and the exposure power of the EUV light which is absorbed by the at least one heated
body is constant in time. This is similar to the respective embodiment of the first
projection lens. Constant in time in this context (and also for the other lens embodiments
described herein) means that the total power of heat to which the mirror is subjected
(e.g. the sum of the heating power of any heater and the absorbed light like EUV light)
is only varying within an interval of the total power selected from the group consisting
of [0%. 20%], [0%. 10%], [0%. 5%] and [0%. 2%]. This is the case if the EUV source
provides EUV light continuously in time, like a synchrotron radiation source. For
pulsed EUV sources like plasma EUV light sources, the total power as mentioned above
is determined by an average over a number of pulses. The number of pulses is selected
such that it is within an interval selected from the group of intervals consisting
of [1, 5], [1, 10], [1, 20], [1, 50] and [1, 100] pulses.
[0077] In a 9
th embodiment of the second projection lens the bodies MB
n and MB
m with the respective zero cross temperatures Tom, Ton are made of the same material.
Further, in a 10
th embodiment of the second lens the lens comprises 4 or 6 reflective optical elements
in form of mirrors. As already mentioned, the number of mirrors also of the second
lens may vary in accordance to the requirements and the principles of the teaching
in connection with the first and second projection lens may be applied to each mirror
or each reflective optical element, especially if used in an EUV lithographic projection
exposure apparatus.
[0078] Further, to minimize the optical aberration especially in projection lenses 20 according
to the second lens of this invention in which at least one mirror or optical element
M
k is heated by a heater 300, it is advantageous to connect the at least one heated
optical element M
k to an actuator for its translational movement. This allows to shift the mirror M
k to compensate a homogeneous heating of the mirror M
k as it was described in connection with Fig. 3a. Further, the heater 300 for heating
the mirror or optical element M
k advantageously comprises heating elements selected from the group consisting of IR
light emitting diodes, Peltier elements, optical fibers, light guide rods and IR lasers,
as will be described in more detail below with the description of Fig. 13. Further,
such heating elements are optionally arranged in one dimension or in two dimensions
at predefined spatial coordinates, forming a grid structure. Advantageously in the
embodiments in which the heating elements are emitting or guiding IR radiation, these
embodiments comprise an optical arrangement to configure the IR radiation, the optical
arrangement comprises arrangement elements selected from the group consisting of collimator,
focusing lens, adjustable lens, mirror and diffractive optical element, wherein the
arrangement elements may be tiltable around at least on axis. Examples of such optical
arrangements are shown in Fig. 13.
[0079] Further, in an alternative embodiment of the above described second projection lenses
the at least one optical element M
k comprises a modification in or on the mirror body MB
k. The modification is selected from the group consisting of recess, blind hole, defined
surface roughness, diffractive structure, spherical protrusion, spherical recess and
surface curvature. The modification, which is described in more detail below in connection
with Fig. 13, advantageously is used to guide e.g. IR radiation to heat the optical
element locally.
[0080] In the following a
third projection lens is described as a part of this invention. This third projection lens makes use of
the knowledge form Fig. 9 which show that the zero cross temperatures of different
mirrors become more different with increasing power of EUV light, if the lens is designed
such that the optical aberration is reduced to a minimum. For the lens of Fig. 6,
as an example, the mirrors M
4 and M
6 should have a zero cross temperature with at least about 1K above the reference temperature
if the lens is subjected to about 16W of EUV light. In contrary mirror M
5 should have a zero cross temperature T
05 of about 34°C, or even higher, which is about 12K or more above the reference temperature
of 22°C. According to embodiments of the first and the second projection lens in accordance
with this invention it is preferred to have a zero cross temperature which is above
the ones shown in Fig. 9. In such cases the heaters of these embodiments can heat
the mirror, e.g. homogenously to the respective zero cross temperatures to minimize
the optical aberration. So if the EUV light power will still increase, which is always
aspired, then the difference in the zero cross temperatures will also increase and
become more than the 11K as it is for the lens which is described in Fig.6 with the
values of Fig. 9. Probably this difference will even double, especially if higher
EUV light power is used in future lenses, so that the difference for the coldest and
the hottest mirror will be about 20K, or even more. In such cases advantageously a
glass ceramic like Zerodur® may be used such that for the coldest and the hottest
mirror the same material is used. The colder mirror of the both is used or operated
at or close to a first zero cross temperature T
10. The hotter mirror is used or operated at or close to the second zero cross temperature
T
20 which is higher than the first one. This means that e.g. mirror M
m and mirror M
n is made of the same material with the two mentioned zero cross temperatures, designated
as T
10mn and T
20mn. As shown in
US 2003/0125184 A1 glass ceramic materials with two zero cross temperatures in a temperature range of
about 0°C to about 100°C exist which have a difference in its zero cross temperatures
T
20 - T
10 of about 20K. The usage of only one material for two mirrors will also reduce the
costs of the projection lens.
[0081] Due to the above advantages, the third projection lens according to this invention
comprises again at least two reflective optical elements M
i, each with a body MB
i and a reflective surface MS
i for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm. As described above the EUV light is reflected
from the reticle when it is illuminated by an illumination system of an EUV-lithographic
projection exposure system. The bodies MB
m, MB
n of at least two reflective optical elements comprise a material with a temperature
dependent coefficient of thermal expansion which is zero at at least two zero cross
temperatures T
10mn and T
20mn. The third lens additionally comprises a support structure for passively or actively
supporting the reflective optical elements M
i, whereas the temperature of at least a part of the support structure is at a reference
temperature T
Ref as described above in connection with e.g. Fig. 4, Fig. 5 and Fig. 3. Further, the
third lens comprises at least two tempering means, preferably heaters, for independently
heating or cooling the at least two bodies MB
n, MB
m of the two reflective optical elements. Further, the third projection lens comprises
a temperature control system for independently controlling the temperature of the
at least two heated or cooled bodies MB
n, MB
m to respective temperatures T
kn and a T
km. As an option at least one of the two zero cross temperatures T
10mn and T
20mn is higher than the reference temperature T
Ref, since the reference temperature is usually in the range of 22°C. This optional embodiment
simplifies the material selection to get a suitable material with the two zero cross
temperatures. Further, during the exposure of the lens with the exposure power of
the EUV light the temperatures T
kn of the body MB
n preferably is within an interval of ± 5K, better ± 2K centered around the first zero
cross temperatures T
10mn, and the temperatures T
km of the body MB
m preferably is within an interval of ± 5K, better ± 2K centered around the second
zero cross temperatures T
20mn. In a further embodiment of the third lens the temperatures T
kn and T
km of the bodies of the reflective optical elements are controlled as close to the respective
zero cross temperatures T
10mn and T
20mn as possible.
[0082] It is mentioned here that in general the reference temperature T
Ref may be set individual for each mirror. This depends also on the used support structure
which holds the mirror. In today's systems the reference temperature is the same for
all mirrors. However, this may change in future. For this reason in accordance with
the present invention the meaning of the reference temperature T
Ref is such that always the reference temperature to the related mirror or reflective
optical element is to be understood.
[0083] Further, the third projection lens according to this invention may also have a cooler
for the cooling of the mirror with the lowest zero cross temperature T
10nm and a heater for the heating of the mirror with the higher zero cross temperature
T
20mn. This has the advantage that the lowest zero cross temperature not necessarily must
be above the reference temperature of 22°C. By applying a cooler a material can be
used in which T
10nm is at about 15°C, which is used e.g. for mirror M
4 or M
6, if referred to Fig. 6, and in which T
20mn is at about 35°C, which is used e.g. for the mirrors M
3 or M
5. This selection of the mirrors results essentially from Fig. 9. Such a material is
e.g. disclosed in
US 2003/0125184 A1. Of course, if a material can be manufactured in such a way that both zero cross
temperatures are in a temperature range of about 22°C to about 40°C, meaning above
the reference temperature T
Ref of the respective mirror or optical element, then the preferred embodiment of the
third lens is that both mirrors M
m and M
n are heated with a heater.
[0084] In a 2
nd embodiment of the third lens the temperature of the bodies MB
n, MB
m, without a heating with the heaters, result in a temperature distributions ΔT
n(x,y,z) = (T
n(x,y,z)-T
Ref), ΔT
m(x,y,z) = (T
m(x,y,z)-T
Ref) of the bodies MB
n, MB
m relative to the reference temperature T
Ref with respective average and maximum temperatures ΔT
nav, ΔT
mav and ΔT
nmax and ΔT
mmax. This is caused by the exposure of the reflective surfaces MS
m and MS
n with the EUV light which is reflected by the illuminated reticle and which comprises
a spatial distribution of angular, polarization and intensity parameters in accordance
with an illumination setting. Further, at least one of the two zero cross temperatures
T
10mn and T
20mn is higher than the maximum of the highest reference temperature T
Ref and the respective absolute average or maximum temperature ΔT
mav + T
Ref or ΔT
mmax + T
Ref, ΔT
nav + T
Ref or ΔT
nmax + T
Ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z), expressed as T
10mn > max(T
Ref, ΔT
mav + T
Ref), T
10mn > max(T
Ref, ΔT
mmax + T
Ref) or T
20mn > max(T
Ref, ΔT
nav + T
Ref), T
20mn > max(T
Ref, ΔT
nmax + T
Ref). Selecting the zero cross temperature in this way has similar advantages as already
described in connection with the first and the second lens of this invention.
[0085] In a 3
rd embodiment of the third projection lens comprising a material in which the zero cross
temperatures T
10mn and T
20mn vary regarding their real values due to manufacturing which results in manufacturing
tolerances ΔT
10mn, ΔT
20mn such that the respective real values are within the intervals T
10mn ± ΔT
10mn and T
20mn ± ΔT
20mn. Due to this tolerances advantageously at least one zero cross temperatures T
10mn and T
20mnis higher than the maximum of the highest reference temperature T
Ref and the respective absolute average or maximum temperature ΔT
mav + T
Ref or ΔT
mmax + T
Ref, ΔT
nav + T
Ref or ΔT
nmax + T
Ref, based on the respective spatial temperature distribution ΔT
m(x,y,z), ΔT
n(x,y,z), which is additionally increased by the absolute value of the respective manufacturing
tolerances ΔT
10mn, ΔT
20mn, expressed as T
10mn > max(T
Ref, ΔT
mav + T
Ref) + |ΔT
10mn| or T
10mn > max(T
Ref, ΔT
mmax + T
Ref) + |ΔT
10mn| or T
20mn > max(T
Ref, ΔT
nav + T
Ref) + |ΔT
20mn| or T
20mn > max(T
Ref, ΔT
nmax + T
Ref) + |ΔT
20mn|.
[0086] As already mentioned above in the description of the second projection lens also
for the third projection lens as an alternative the selection of the zero cross temperature
can done by T
0n > max(T
Ref, T
av n + T
ref) or T
0m > max(T
Ref, T
av m +T
ref), whereby T
av m and T
av n are the respective average temperatures of mirrors M
m and M
n as described above e.g. in connection with Fig. 7 or Fig. 3. However, if the maximum
temperature instead of the average temperature is considered in the selection process
also the third lens then is more also robust, e.g. regarding changes in exposure powers
to higher values. Like the previous embodiments of the lenses in accordance with this
invention, instead of the absolute maximum temperatures also the absolute average
temperature may be sufficient, but in this case the third lens will be less robust
against a raise of temperature of the mirrors which may result from higher exposure
power.
[0087] Similar as the first and the second projection lens of this invention also the third
projection lens in a 4
th embodiment is controlled such that at a time before the projection lens is subjected
to the exposure power of the EUV light the temperature T
kn or T
km of the at least one heated body MB
n, MB
m is controlled to its value by heating the heater with a first heating power. In a
5
th embodiment the control is such that during the time of the exposure of the third
projection lens with the exposure power of the EUV light the heating power of the
heater with the initial first heating power is less than the first heating power.
Alternative to the 4
th and the 5
th embodiments of the third projection lens in a 6
th embodiment of the third lens the temperature control system controls at least one
of the temperatures T
km and T
kn such that the heating power of the respective heater and the exposure power of the
EUV light absorbed by the at least one temperature controlled body MB
m or MB
n is constant in time. The advantages of the 4
th to the 6
th embodiments of the third lens are already mentioned in connection with the first
and the second projection lens.
[0088] In a 7
th embodiment of the third projection lens of this invention the lens is designed to
be exposed with an exposure power of more than 8 W of EUV light with a wavelength
in a wavelength range of less than 50 nm. Especially Fig. 9 shows that for higher
EUV light power to which the lens is exposed, the third embodiment can be used due
materials which is available today, as are already mentioned.
[0089] In an 8
th embodiment of the third projection lens the absolute value of the difference between
the zero cross temperatures T
10mn, T
20mn is chosen more than 6K, expresses as abs(T
10mn - T
20mn) > 6K. In this case the projection lens is designed to be exposed with an exposure
power of more than 8 W of EUV light with a wavelength in a wavelength range of less
than 50 nm. Figure 9 shows an example of such a lens. Further, in a 9
th embodiment of the third projection lens 4 or 6 reflective optical elements are mirrors.
Alternative or in addition the embodiments of the third projection lens, as described
above, may be operated such that, e.g. at a time before the projection lens is subjected
to the exposure power of the EUV light, at least one of the temperature controlled
bodies MB
n, MB
m is controlled to its value by cooling with the respective tempering means with a
first cooling power. Further, the first cooling power can be increased by the tempering
means at a time when the projection lens is subjected to the EUV exposure light. The
cooling power describes the heat transfer per time from the temperature controlled
body to the tempering means. Again the number of mirrors for the third projection
lens may vary in accordance to the requirements. The principles used in third projection
lens may be applied to each mirror or each reflective optical element, especially
if used in an EUV lithographic projection exposure apparatus.
[0090] Further, to minimize the optical aberration especially in projection lenses 20 according
to the third lens of this invention in which at least one mirror or optical element
M
k is heated or cooled by a heater 300 or tempering means, it is advantageous to connect
the at least one heated and/or cooled optical element M
k to an actuator for its translational movement. This allows to shift the mirror M
k to compensate a homogeneous heating or cooling of the mirror M
k as it was described in connection with Fig. 3a. Further, tempering means, as e.g.
the heater 300 for heating the mirror or optical element M
k, advantageously comprises heating elements selected from the group consisting of
IR light emitting diodes, Peltier elements, optical fibers, light guide rods and IR
lasers, as will be described in more detail below with the description of Fig. 13.
Further, such heating elements are optionally arranged in one dimension or in two
dimensions at predefined spatial coordinates, forming a grid structure. Advantageously
in the embodiments in which the heating elements are emitting or guiding IR radiation,
these embodiments comprise an optical arrangement to configure the IR radiation, the
optical arrangement comprises arrangement elements selected from the group consisting
of collimator, focusing lens, adjustable lens, mirror and diffractive optical element,
wherein the arrangement elements may be tiltable around at least on axis. Examples
of such optical arrangements are shown in Fig. 13.
[0091] Further, in an alternative embodiment of the above described third projection lenses
the at least one optical element M
k comprises a modification in or on the mirror body MB
k. The modification is selected from the group consisting of recess, blind hole, defined
surface roughness, diffractive structure, spherical protrusion, spherical recess and
surface curvature. The modification, which is described in more detail below in connection
with Fig. 13, advantageously is used to guide e.g. IR radiation to heat the optical
element locally.
[0092] Further the present invention is also related to a method to configure a projection
lens of an EUV lithographic projection exposure system. The following method is based
on the teaching of the previous embodiments of the invention. The configuration method
comprises the following steps:
- I a first step the number of reflective optical elements Mi of a EUV projection lens is determined. Some requirements are that the projection
lens projects an object field of a give size which is on a reticle onto an image field
of a given size on a substrate. For the projection an EUV projection light beam with
a wavelength of less than 50 nm is used. The projection requirement is e.g. a predetermined
spatial resolution with a predetermined quality.
- In a second step the surface figure and surface shape of each reflective optical element
Mi is determined based on the geometric data of the object field and the image field
and the predetermined spatial resolution.
- In a third step the substrate material for each reflective optical element Mi with its shape and size is selected, wherein the material is selected by consideration
of thermal expansion.
- In a fourth step at least on substrate material is selected from a group of materials
which have a temperature dependent coefficient of thermal expansion which is zero
at a zero cross temperature T0m. This material is preferably used for mirrors with a high thermal load.
- In a fifth step the maximum thermal load for each reflective optical element Mi is determined which is expected during the projection of the object field onto the
image field under various conditions of the EUV projection exposure system, like EUV
light power, transmission or reflection of the reticle, various illuminations settings
and various pattern structures on the reticle.
- In a sixth step the spatial temperature T(x,y,z) for each reflective optical element
Mi based on the 5th step, considering its thermal load , is determined together with its maximum and
its average temperature values Ti max and Ti av,
- In a seventh step the at least one material with the zero cross temperature T0m is selected based on the zero cross temperature T0m. The selection is done such that the maximum temperature or the average temperature
Tm max and Tm av of the temperature T(x,y,z) of the optical element Mm related to the at least one substrate material is lower than the zero cross temperature
T0m, expressed as Tm max < T0m or Tm av < T0m.
- In the eighth step the mirrors and the lens are formed with the selected materials.
[0093] In a preferred method the configuration method comprises the additional steps in
which the at least one material is selected such that the zero cross temperatures
T
0m is higher than the maximum temperature or the average temperature T
max and T
av increased by an absolute value of respective manufacturing tolerances ΔT
0m, to manufacture a material with the zero cross temperature T
0m, expressed as T
0m > T
m max + |ΔT
0m | or T
0m > max(T
Ref, T
mmax)+ |ΔT
0m|. With this material selection also variations of the zero cross temperatures T
0m are considered, since they vary regarding its real value due to manufacturing process
parameters, as e.g. described in
US 2003/0125184 A1. The real values of the zero cross temperatures T
0m are within the intervals T
0m ± ΔT
0m.
[0094] The configuration method may comprise that the one material with the zero cross temperature
T
0m is selected such that it comprises a second zero cross temperature T
20m such that the absolute value of the difference between the zero cross temperature
and the second zero cross temperature is less than 40 K, expressed as abs (T
0m - T
20m) < 40 K. This has the advantage that such a material is applicable for two mirrors
of the EUV projection lens, whereas the two mirrors have different thermal load which
result in very different zero cross temperatures to minimize optical aberration, as
described in connection with Fig. 9.
[0095] Further, the configuration method may comprise that the material with the second
zero cross temperature is used as substrate material for at least one additional reflective
optical element, as it was just explained.
[0096] The configuration method may comprise a step in which a heater 300 and a temperature
control system 200 is selected such that the at least one material with the zero cross
temperature is heatable to its zero cross temperature.
[0097] In the following various embodiments of the heater 300 are described. Further, also
heating methods and special bodies for the reflective optical element M
k are shown, which allow the heating of the reflective element or mirror in such a
way that the thermal induced optical aberrations become minimal. These further aspects
are also treated a parts of the present invention.
[0098] Fig. 10 schematically shows a side view a reflective optical element M
k like a mirror 421 of an EUV projection lens, as e.g. shown in Fig. 4 and Fig. 5.
The optical element comprises a reflective surface MS
k which could be a mirror surface 450 or also a diffractive surface. In general, also
on all the reflective optical elements, in accordance to this invention, the reflective
surface can comprise diffractive structures to form a diffractive optical element
for the incident radiation. The incident radiation 1000 can be a EUV light projection
beam 4 (see Fig. 1), or it can be light of another wavelength like e.g. infrared light.
In Fig. 10 in addition, support means are schematically shown like such ones which
are described in connection with Fig. 4 and Fig. 5 why the same reference numerals
are used. These support means are e.g. linking points 451, linking elements 471 or
a bipod structure 461 as described in Fig. 4. Also a support element 480 and a part
of the housing structure 481 is shown. Further, a heater or in general a first tempering
element 300 is shown. Parts and some embodiments of such a heater or first tempering
element 300 are already described together with Fig. 5. The difference between a heater
and a tempering element is that the heater only can heat in a controlled way, whereas
the tempering element is able to heat and cool in a controlled way. Heating in this
context means that thermal energy is transferred from the heater or tempering element
to is surrounding. Cooling means that thermal energy is transferred from the surrounding
of the heater or tempering element to the heater or tempering element, and the heater
or the tempering element is controllable in such a way that its temperature is lower
than the temperature of the surrounding. Further, the embodiment as shown in Fig.
10 comprises a cooler or second tempering element 350. The cooler 350 or second tempering
element is preferably arranged between the heater or first tempering element 300 and
the support element 480 and/or the housing structure 481 (not shown) and /or the support
means 451, 461, 471 (not shown, see Fig. 5). If the heater or first tempering element
300 is used to influence the temperature distribution of the reflective optical element
M
k then there is a risk that also the temperature of other elements in the surrounding
of the reflective element M
k is changed. Such an element can be e.g. the support element 480, the housing structure
481 or the support means 451, 461, 471. However, some of these elements have to be
at a well controlled constant temperature to keep the reflective optical element or
the mirror M
k, 421 in its position. As mentioned above, this position has to be constant within
a nanometer or even sub-nanometer range. For this reason these elements are designated
as temperature sensitive elements. Any heating and/or cooling of the surrounding of
the reflective optical element or the mirror M
k, 421 to influence its temperature or temperature distribution, e.g. with the heater
or first tempering element 300, may change this position. For this reason the cooler
or second tempering element 350 is made such that it absorbs any thermal effects which
are caused by the heater or first tempering element 300. This means that on the side
351 of the cooler 350 or of the second tempering element, which is oriented to the
direction of the temperature sensitive elements like the support element 480 and/or
the housing structure 481 and/or the support means 451, 461, 471, the temperature
of the cooler or second tempering element is kept constant, resulting in a constant
temperature of the temperature sensitive element such that the position of the respective
optical element M
k is constant on the nanometer or even sub-nanometer level. With this measure the temperature
variation of these temperature sensitive elements can be reduced even if e.g. the
heater or first tempering element changes its temperature to influence the temperature
or the temperature distribution of the reflective optical element or mirror M
k, 421, to achieve the advantages as described in connection with the above described
projection lenses of the present invention.
[0099] Due to the advantages of the embodiment shown in Fig. 10 the present invention also
relates to a fourth projection lens of an EUV-lithographic projection exposure system
which comprises a plurality of reflective optical elements M
i. Each reflective element M
i comprises a body MB
i and a reflective surface MS
i to project an object field on a reticle onto an image field on a substrate if the
projection lens is exposed with an exposure power of EUV light with a wavelength in
a wavelength range of less than 50 nm which is reflected from the reticle while the
reticle is illuminated by an illumination system of the EUV-lithographic projection
exposure system. The lens further comprises support means which comprises a temperature
sensitive element selected from the group consisting of linking points 451, bipod
structures 461, linking elements 471, a support element 480 and a housing structure
481, for passively or actively supporting at least one optical element M
k. Further, the temperature sensitive element is controlled to a constant temperature
or to a predefined temperature. The lens further comprises a first tempering element
300 for heating and/or cooling the at least one optical element M
k to a temperature T
k, and a second tempering element 350 for tempering the temperature sensitive element
to the constant temperature or to the predefined temperature. Further, the second
tempering element 350 is spatially arranged between the temperature sensitive element
and the first tempering element 300.
[0100] In a further second embodiment of the fourth projection lens the heated or cooled
reflective optical element M
k comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a zero cross temperature T
0k which is different from the constant or predefined temperature of the temperature
sensitive element. Preferably in a further third embodiment of the fourth projection
lens the temperature of the temperature sensitive element in the fourth projection
lens is at a reference temperature T
Ref. The reference temperature T
Ref has the same meaning as for the other projection lenses of this invention or as are
described herein. Preferably but not necessarily the reference temperature T
Ref = 22°C, or at the temperature of the clean room in which the lithographic projection
exposure apparatus is operated for mass production.
[0101] A further fourth embodiment of the fourth projection lens comprising the features
of the above second and third embodiments, and in addition the feature that without
tempering the body MB
k with the first tempering element 300, the exposure of the reflective surface MS
k with EUV light, being reflected by the illuminated reticle and comprising a spatial
distribution of angular, polarization and intensity in accordance with an illumination
setting, results in a temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) of the body MB
k relative to the reference temperature T
Ref with an average and maximum temperature ΔT
kav and ΔT
kmax . Further, the zero cross temperatures T
0k in this embodiment is higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature added by the reference temperature,
resulting in ΔT
kav + T
ref or ΔT
kmax + T
Ref based on the spatial temperature distribution ΔT
k(x,y,z), which is expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) or T
0k > max(T
Ref, ΔT
kmax + T
Ref).
[0102] In a further fifth embodiment of the fourth projection lens the material with the
zero cross temperature T
0k varies regarding its real value of the zero cross temperature due to manufacturing
processes. This results in a manufacturing tolerance ΔT
0k such that the real value is within the interval T
0k ± ΔT
0k. In this embodiment the zero cross temperatures T
0k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature (based on the spatial temperature
distribution ΔT
k(x,y,z)) added by the reference temperature, resulting in ΔT
kav + T
Ref or ΔT
kmax + T
Ref, the maximum is increased by the absolute value of the manufacturing tolerance ΔT
0k, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) + |ΔT
0k|, T
0k > max(T
Ref, ΔT
kmax + T
Ref) + |ΔT
0k|.
[0103] In a further sixth embodiment of the fourth projection lens (and its embodiments)
the zero cross temperature T
0k of the reflective optical element M
k is lower than the reference temperature T
Ref, or is at least 6 K higher than the reference temperature. In the case that the zero
cross temperature is lower than the reference temperature the reflective optical element
M
k is cooled by the first tempering mans to a temperature close to this zero cross temperature.
This feature of the fourth projection lens can be used in the third projection lens
of the present invention for the cooling of the mirror with the lowest zero cross
temperature as it was described above. If the zero cross temperature T
0k is at least 6 K above the mentioned reference temperature this feature of the fourth
projection lens can be used in a projection lens in accordance with the first projection
lens in which the zero cross temperatures of two reflective elements differ at least
by 6 K and one of the two reflective elements has a zero cross temperature close to
or at the reference temperature. As mentioned in the description of the first projection
lens of the present invention such a projection lens is designed for an EUV exposure
power of more than 8 W (see also Fig. 9 with description).
[0104] In an additional seventh embodiment of the fourth projection lens (and its embodiments)
the reflective optical element M
k is (in at least one spatial dimension) homogeneously subjected to a heat transfer
caused by the first tempering element 300. Such a homogeneous heat transfer homogeneously
heats or cools the optical element M
k which results in a constant temperature distribution of the reflective optical element
M
k along the at least one dimension, if only the influence of the first tempering element
300 is considered. This variant of the fourth projection lens can be used in the first,
second and third projection lens to e.g. homogeneously heat up the reflective optical
element to or close to its zero cross temperature, as it was described in connection
with these projection lenses, and as it was schematically described with Fig. 3a to
3l and Fig. 5. Advantageously, in a further embodiment of the fourth projection lens
and its various embodiments the optical element M
k is connected to an actuator for its translational movement. This is to minimize optical
aberration of the projection lens or the optical element M
k for the case that the optical element is homogeneously heated or cooled to a temperature
different from the reference temperature T
Ref, as is was described e.g. in connection with Fig. 3a and Fig. 3b.
[0105] As shown in Fig. 10 in a preferred eighth embodiment of the fourth projection lens
and its embodiments the first tempering element 300 is located on a side of the body
MB
k of the at least one optical element M
k which is opposite to its reflective surface MS
k. This is a similar arrangement of the first tempering element 300 as it is described
in Fig. 5 for the heater 300. In the fourth projection lens and its embodiments preferably
the first tempering element 300 comprises a Peltier element or a radiation source,
emitting a radiation comprising a wavelength to which the body MB
k of the at least one optical element M
k is semitransparent. As shown in Fig. 10, in a further embodiment of the fourth projection
lens the second tempering element 350 is located on a side of the first tempering
element 300 which is opposite to the body MB
k of the at least one optical element M
k.
[0106] In one embodiment in accordance with Fig. 10 the tempering element 300 may be a Peltier
element or may comprise a Peltier element as already mentioned. The Peltier element
may heat or cool the surrounding around its surface side 362 which is oriented into
the direction of the reflective element or mirror M
k, 421. Preferably the Peltier element extends parallel or approximately parallel to
the surface of the reflective element M
k, 421 which is opposite of the reflective surface MS
k, 450. If the Peltier element has at least such a size so that the reflective surface
or even the reflective element can be covered from one side then a homogenous heating
and/or cooling of the reflective element can be done which results in all the advantages
as described herein (e.g. in connection with Fig. 3a). To make the Peltier element
more efficient it is preferably coupled to the cooler 350, or in general to the second
tempering element by e.g. coupling one of its surfaces 361 to one of the surfaces
352 of the cooler 350 or the second tempering element. The cooler 350 or in general
the second tempering element may have a kind of a sandwich structure such that the
surface 352 which is in contact with the first tempering or Peltier element 300 is
separated from the surface 351 which is oriented into the direction of the temperature
sensitive elements, like the support element 480, the housing structure 481 or the
support means 451, 461, 471. In a further embodiment the first tempering element 300
may comprise several Peltier elements. Preferably the Peltier elements are arranges
side by side in at least one dimension, to form an array-like arrangement. Arrangements
of the Peltier elements in two or even three dimensions are also of advantage. Preferably
each Peltier element of such an arrangement is controllable by a control system like
e.g. the temperature control system as described in Fig. 5. In this case a controllable
temperature profile on the side which is directed to the reflective element or mirror
can be adjusted. This will influence the temperature distribution within the reflective
element or mirror M
k, 421 in a controlled way. Such a heater or tempering element can be used for the
temperature control of the reflective element or mirror M
k, 421 in accordance to the teaching of this invention in such a way that the thermal
induced optical aberration or the imaging errors are minimized. The usage of the described
Peltier element 300 or an arrangement of Peltier elements as a tempering means in
the third projection lens according to this invention will have the advantage that
the mirror with the low zero cross temperature T
10mn (according to the third projection lens of this invention) can be cooled down to
this temperature or even lower, which is important if the zero cross temperature is
below the reference temperature T
Ref. Further, the mirror with the high zero cross temperature T
20mn (or a zero cross temperature higher than the reference temperature T
Ref) can be heated up to this or the respective operation temperatures as described above
in connection with one of the projection lenses according to this invention.
[0107] In a further embodiment of the fourth projection lens and its embodiments described
above, the projection lens comprises a pressure control system for the control of
the pressure Δp within a surrounding of the at least one reflective optical element
M
k. Such a pressure control system will be described below in connection with Fig. 11.
The pressure control is based on a parameter selected from the group consisting of:
The temperature of the reflective optical element M
k, the time, a parameter which directly or indirectly influences the temperature of
the optical element M
k, an illumination setting, a change of the reticle, thermally or mechanically induced
optical aberration data of the optical element M
k or the projection lens and an output parameter from a model. The model input comprises
data selected from the group consisting of: The temperature of the reflective optical
element M
k, the time, a parameter which directly or indirectly influences the temperature of
the optical element M
k, an illumination setting, thermally or mechanically induced optical aberration data
of the optical element M
k or the projection lens and a change of the reticle. Further, the pressure control
system preferably comprises a gas inlet and/or a gas outlet nearby the at least one
optical element M
k.
[0108] The fourth projection lens according to this invention preferably is operated such
that the temperature T
k of the optical element M
k is controlled to its value by heating the first tempering element with a first heating
power at a time before the projection lens is subjected to the exposure power of the
EUV light. Then, during the time when the projection lens is subjected to the exposure
power of the EUV light, the heating power of the first tempering element is less than
the first heating power. Further, in a preferred embodiment of the fourth projection
lens and its various embodiments the temperature T
k of the at least one optical element M
k which is heated and/or cooled by the first tempering element 300 is the zero cross
temperature T
0k.
[0109] Fig. 11 schematically shows a further embodiment of the present invention similar
as shown in Fig. 10 why like elements are designated with the same reference numerals.
In the following the description focuses only to the differences to the embodiment
of Fig. 10. The elements not described and its functions are as the ones described
in Fig. 10. In the embodiment of Fig. 11 there is no heater or tempering means. The
temperature of the reflective optical element or mirror M
k, 421 is controlled by pressure control of the pressure within the surrounding of
the reflective element or mirror M
k, 421, designated as Δp. In this case the pressure can be controlled e.g. as a function
of the temperature of the reflective element or mirror M
k, 421, as a function of time or a function of other parameters which directly or indirectly
influence the temperature of the reflective element or mirror M
k, 421. Further, the control system which controls the pressure may comprise a model
which uses input data like the mentioned function variables to optionally adjust the
model and to provide output parameters like the pressure or any parameter which directly
or indirectly influence the pressure in the mentioned surrounding. From the above,
the present invention also relates to a
fifth projection lens. The fifth projection lens is a projection lens of an EUV-lithographic projection
exposure system. The lens comprises a plurality of reflective optical elements M
i, each comprises a body MB
i and a reflective surface MS
i for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm, when the light is reflected from the reticle
while illuminated by an illumination system of the EUV-lithographic projection exposure
system. The lens further comprises support means for passively or actively supporting
at least one optical element M
k, a pressure control system (as described in connection with the embodiment of Fig.
11) for the control of the pressure Δp within a surrounding of the at least one reflective
optical element M
k, wherein the control is based on a parameter selected from the group consisting of:
The temperature of the reflective optical element M
k, the time, a parameter which directly or indirectly influence the temperature of
the optical element M
k, an illumination setting, a change of the reticle, thermally or mechanically induced
optical aberration data of the optical element M
k or the projection lens and an output parameter from a model. Further, the model is
using input data selected from the group consisting : The temperature of the reflective
optical element M
k, the time, a parameter which directly or indirectly influence the temperature of
the optical element M
k, an illumination setting, thermally or mechanically induced optical aberration data
of the optical element M
k or the projection lens and a change of the reticle.
[0110] The following describes the fifth projection lens in more detail with various modified
embodiments also referring to Fig. 11.
[0111] In a second embodiment of the fifth projection lens the support means comprising
a temperature sensitive element,(as described in connection with Fig. 10) selected
from the group consisting of linking points 451, bipod structures 461, linking elements
471, support element 480 and housing structure 481, for passively or actively supporting
the at least one optical element M
k, wherein the temperature sensitive element is controlled to a constant or predefined
temperature by a cooler 350. Preferably the cooler 350 is spatially arranged between
the temperature sensitive element and the at least one optical element M
k. In the fifth projection lens and its various embodiments the pressure Δp within
the surrounding of the at least one optical element M
k is in the range of 0.1 Pa to 10 Pa, more preferably in the range between 1 Pa and
5 Pa. The distance between the at least one optical element M
k and the cooler 350 preferably is in the range of 1 mm to 10 mm, more preferably in
the range between 3 mm and 5 mm. Further, the pressure control system comprises a
gas inlet and/or a gas outlet nearby the at least one reflective optical element M
k. With the gas inlet and/or gas outlet (not shown in Fig. 11) the pressure within
the surrounding of the at least one optical element M
k can be adjusted. In a further preferred embodiment of the fifth projection lens the
distance of the cooler 350 between the at least one reflective optical element M
k and the cooler 350 is adjustable to control a heat transfer between these elements.
[0112] Further, similar as for the fourth projection lens and its embodiments as described
with Fig. 10, in the fifth projection lens the at least one reflective optical element
M
k also comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a zero cross temperature T
0k. Generally this zero cross temperature is different from the constant or predefined
temperature of the temperature sensitive element, whose temperature is preferably
but not necessarily at a reference temperature T
Ref, as it was already mentioned in connection with the fourth projection lens of this
invention which was described in connection with Fig. 10.
[0113] The fifth projection lens advantageously offers the possibility that the pressure
Δp (which is controlled by the control system) is such that the temperature of the
at least one reflective optical element M
k is at its zero cross temperature.
[0114] Usually the surrounding of the reflective element or mirror M
k, 421 comprise a gas with a pressure in the range of about 1 to 5 Pa (Pascal), preferably
about 3.5 Pa. The cooler 350 is usually shielding the temperature sensitive element
such that any temperature change of the mirror 421 will have no influence on them,
as already described with Fig. 10. For this preferably the cooler 350 is spatially
arranged between the temperature sensitive element and the at least one optical element
M
k.
[0115] The distance between the at least one optical element supported by the support means
or the mirror 421 and the cooler 350 is about 3 to 5 mm. Within this space there is
the gas pressure as mentioned. As a gas usually hydrogen is used. If, in the case
of a hydrogen gas, the pressure is changes by about ±1 Pa then the thermal resistance
of the gas will change by about ±25%. By the usage of a pressure control system to
control the pressure in the direct surrounding of the mirror 421, the mirror can be
controlled regarding its absolute temperature and regarding its temperature distribution
as a function of time. As an example, at the start of the EUV projection process the
mirror 421 is at a lower temperature as it is in a steady state. In this case the
pressure is reduced so that the mirror heats up faster to its steady state temperature.
As another example, if the illumination setting and/or the reticle is changed, most
probable also the power will change to which the EUV projection lens is subjected
as it was described above. In such a case the mirror 421 will heat up to a higher
or to a lower steady state temperature. In the first case the pressure is increased
to reduce the thermal resistance between the cooler 350 and the mirror 421. In the
second case the pressure will be reduced to increase the thermal resistance of the
gas surrounding to bring the mirror to its best steady state temperature which is
closest to the zero cross temperature (this was explained with Fig. 7). Applying the
regulation of the gas pressure in the surrounding of the mirror 421 will influence
the steady stated temperature. Ideally the steady state temperature should be the
zero cross temperature to minimize the optical aberration. As a further application,
also small variations in the zero cross temperature of a certain mirror M
k, e.g. due to manufacturing tolerances, may be compensated in a way that the pressure
in the direct surrounding of this mirror is adjusted such that in the steady state
the average temperature T
avk of this mirror fits best to the zero cross temperature. Such a pressure control requires
that the pressure in the direct surrounding of the individual mirrors or reflective
optical elements of an EUV lens can be changed independently. Practically this is
done by gas inlets and gas outlets nearby the mirrors. From this in a further embodiment
of the fifth projection lens the pressure control system comprises a gas inlet and
a gas outlet nearby the at least one reflective optical element M
k which is supported by the support means.
[0116] In further embodiments of the fifth projection lens also the distance of the cooler
surface 352, or in general the distance between the cooler 350 and the mirror 421
or the reflective optical element M
k may be adjusted to control the heat transfer between these elements.
[0117] Fig. 12a shows the transmission of Zerodur® for a transmission path of 5 mm and 25
mm. It shows that Zerodur® has an about constant absorption coefficient for light
with a wavelength in the range of 700 nm up to about 2µm (herein further designated
as infrared or IR radiation or IR light). The attenuation length in Zerodur® for IR
light with a wavelength in this range is about 50 mm to about 100 mm. This results
from Fig. 12a. Fig. 3d and Fig. 3h also show typical mirror sizes of mirrors used
in an EUV projection lens. The diameters are typically in the range of 200 mm to 600
mm, and the thickness is up to 100 mm. This means that if IR light passes a distance
of 50 mm to about 100 mm in Zerodur® material then 63% of its energy is absorbed along
its path. So the attenuation length fits well to the size of the mirrors of an EUV
lens such that the mirror, if made of Zerodur® or if comprising Zerodur®, can be heated
by the mentioned IR light. This is because the IR light deposits its energy over a
distance of about 50 mm up to even 100 mm and more. Such a distance can be warmed
up simultaneously in a more or less homogenous way. This means that a mirror body
MB
k of a mirror M
k, as e.g. shown in Fig. 5, Fig. 10 or Fig. 11, is semitransparent for a radiation
which comprises a wavelength in the infrared range, as shown in Fig. 12a. To make
use of this effect Fig. 12b schematically shows a further embodiment of the present
invention in which a reflective optical element or a mirror M
k, 421 is coated with a coating C on or on almost its entire surface to make the mirror
heatable with IR radiation. The coating C differs from the reflective surface MS
k, 450 which may comprise also a coating in the form of a multilayer to reflect the
EUV light.
[0118] The coating C is selected such that the infrared radiation IR is reflected. As a
coating material a very thin metal layer can be used. Other coatings which reflect
IR radiation can also be used. Further, the coating and the wavelength of the IR radiation
can be adapted such that its reflection is optimized. The coating C has the function
that the IR radiation cannot leave the mirror body MB
k and that mirror is heated more homogenous due to the various reflections which are
shown in Fig. 12b as 1002. With this method the IR radiation almost instantaneously
and totally deposits its energy within the mirror body MB
k. To get the IR radiation into the mirror body MB
k at least one surface area of it is not coated or the coating is partly transparent
for the IR radiation. Such surface areas are designated by 1004 and 1006 and are called
IR windows. The IR window or a plurality of IR windows 1004, 1006 are positioned on
a suitable position on the mirror which considers the attenuation length of the IR
radiation within the mirror body material, the geometrical form and the size of the
mirror. Also any limitations regarding construction space is considered. However,
since the attenuation length is comparatively large, or in other words in the range
of the size of the mirror, the position of the IR window is not so critical. Especially,
the position can be on the side of the mirror body MB
k on which the reflective surface MS
k, 450 of the reflective element or mirror is arranged, as shown in the example of
Fig. 12b. This has the advantage that also the construction space in front of the
mirror can be used to couple the IR radiation into the reflective element or mirror.
Most other heater or tempering means cannot be used in this space since they will
block or shadow the EUV projection beam 1000. Preferably the IR window surrounds the
reflective surface MS
k, 450, as schematically shown in Fig. 12b. As a further option the IR window comprises
a certain surface roughness or a diffractive structure to scatter or distribute the
IR radiation within the mirror body. Further, the IR radiation may at least partly
share the same construction space as the EUV projection beam 1000, as is shown in
Fig. 12b for the right IR beam. As IR radiation source any source like Lasers, IR-diodes,
filaments or lamps etc. can be used. Depending on the IR source a suitable optical
arrangement can be used to configure the IR radiation such that it can be coupled
into the reflective element or into the mirror M
k, 421 through the IR windows. Such an optical arrangement may comprise lenses and
mirrors or in general refractive, diffractive and/or reflective optical elements.
In addition or alternative, such an optical arrangement may also comprise quartz fibers
or optical fibers (in general light guides) e.g. to transport the IR radiation from
the IR source to the IR windows 1004, 1006. In this case then the IR source can be
positioned even outside the EUV projection lens or outside the EUV lithographic projection
system. A reflective optical element or a mirror M
k, 421 as described with Fig. 12b has the advantage that there is no mechanical contact
of the heater or tempering element or tempering means (which comprises the IR source
and an optional optical arrangement to configure the IR light) with the reflective
element or the mirror M
k.
[0119] In further embodiments of the present invention the reflective element or mirror
of Fig. 12b can be used together with the tempering elements or tempering means e.g.
the heater 300 of the embodiment of Fig. 10 and/or with the cooler 350 as described
there, or as described in the embodiment of Fig. 11. In addition, or as an alternative,
also the pressure control as described in Fig. 11 can be used together with the embodiments
of Fig. 12b. All these embodiments can advantageously be used in an EUV projection
lens, especially in one as described above in accordance to this invention, preferably
in the first, second and third projection lens according to this invention, having
the advantage that the thermal induced optical aberration is minimized.
[0120] The above discussion of Fig. 12a and Fig. 12b result in a
sixth projection lens according to this invention, and which is illustrated in Fig. 12b. The first embodiment
of the sixth projection lens for an EUV-lithographic projection exposure system comprises
a plurality of reflective optical elements M
i. Each reflective optical element M
k comprises a body MB
i and a reflective surface MS
i for projecting an object field on a reticle onto an image field on a substrate, if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm, which is reflected from the reticle while
the reticle is illuminated by an illumination system of the EUV-lithographic projection
exposure system. Further, the at least one reflective optical element M
k comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a zero cross temperature T
0k. In addition, the body MB
k of the optical element M
k is semitransparent to an IR radiation, and the at least one reflective optical element
M
k with its body MB
k comprises a coating C on or on almost its entire surface of the body MB
k. The coating C reflects IR radiation inside the body MB
k.
[0121] A second embodiment of the sixth projection lens comprises an IR light source or
comprises an optical arrangement to form an IR light path. The IR light source or
the IR light path couples IR radiation into the body MB
k which comprises the coating C. In a preferred embodiment the IR light source or the
optical arrangement comprises an element selected from the group consisting of: Laser,
IR-diode, filament, lens, mirror, refractive element, diffractive element, reflective
element, light guide and optical fiber. Further, the body MB
k preferably comprises a surface area 1004, 1006 not coated with the coating C, or
comprises a surface area 1004, 1006 with a coating being semitransparent to the IR
radiation, for coupling in the IR radiation into the body MB
k. Preferably the coating C comprises a metal.
[0122] In a further embodiment of the sixth projection lens the surface area 1004, 1006
is arranged on the side of the body MB
k which comprises the reflective surface MS
k. Alternative or in addition, the surface area 1004, 1006 surrounds the reflective
surface MS
k. Further, the surface area 1004, 1006 may comprise a surface roughness to scatter
the IR radiation into the body, or the surface area may comprise a diffractive structure
to distribute the IR radiation within the body MB
k by diffraction.
[0123] In a further embodiment of the sixth projection lens the construction space nearby
the reflective surface MS
k is illuminated by the IR radiation and the EUV light. Preferably the IR source is
arranged outside the projection lens or outside the EUV-lithographic projection exposure
system.
[0124] Further, as in the first to fifth projection lenses described above, also in the
sixth projection lens the optical element M
k optionally is connected to an actuator for its translational movement.
[0125] Similar as the first to fifth projection lens also the sixth projection lens may
comprise embodiments which comprises a cooler 350 located on a side of the body MB
k of the at least one optical element M
k which is opposite to its reflective surface MS
k. Further, the distance of the cooler 350 to the at least one reflective optical element
M
k preferably is adjustable for the control of the heat transfer between these elements.
Alternative or in addition, the sixth projection lens (and its embodiments) comprises
a pressure control system for the control of the pressure Δp within a surrounding
of the at least one reflective optical element M
k, Further, the mentioned pressure control system may comprise a gas inlet and/or a
gas outlet nearby the at least one optical element M
k.
[0126] Without radiating the body MB
k of the sixth projection lens with IR radiation, the exposure of the reflective surface
MS
k with EUV light (which is reflected by the illuminated reticle, and which comprises
a spatial distribution of angular, polarization and intensity in accordance with an
illumination setting) results in a temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) of the body MB
k with the temperature T
k(x,y,z) relative to a reference temperature T
Ref. The temperature distribution comprises an average and maximum temperature ΔT
kav and ΔT
kmax ,. Preferably the zero cross temperature T
0k is higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature ΔT
kav + T
ref or ΔT
kmax + T
Ref, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) or T
0k > max(T
Ref, ΔT
kmax + T
Ref). Further, if the material with the zero cross temperature T
0k varies regarding its real value of the zero cross temperature due to manufacturing,
resulting in a manufacturing tolerance ΔT
0k such that the real value of the zero cross temperature T
0k is within the interval T
0k ± ΔT
0k, then the zero cross temperatures T
0k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature ΔT
kav + T
Ref or ΔT
kmax + T
Ref,, wherein the maximum is increased by the absolute value of the manufacturing tolerance
ΔT
0k, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) + |ΔT
0k|, T
0k > max(T
Ref, ΔT
kmax + T
Ref) + |ΔT
0k|.
[0127] In a further embodiment of the sixth projection lens (and its various embodiments)
the temperature T
k of the optical element M
k is controlled to its value by irradiating the optical element MB
k with a first IR radiation power at a time before the projection lens is subjected
to the exposure power of the EUV light. Optionally the IR radiation power is less
than the first IR radiation power during the time when the projection lens is subjected
to the exposure power of the EUV light.
[0128] Further, the present invention relates to a mirror (as shown in Fig. 12) which comprises
a body MB
k and a reflective surface MS
k, and material with a temperature dependent coefficient of thermal expansion which
is zero at a zero cross temperature T
0k. Further, the body MB
k of the optical element M
k is semitransparent to an IR radiation, and the body MB
k comprises a coating C on or on almost its entire surface of the body MB
k, wherein the coating C reflects IR radiation inside the body MB
k, and wherein the mirror is adapted for a projection lens of an EUV-lithographic projection
exposure system for projecting an object field on a reticle onto an image field on
a substrate if the projection lens is exposed with an exposure power of EUV light
with a wavelength in a wavelength range of less than 50 nm. Optionally the mirror
body MB
k comprises a surface area 1004, 1006 which is not coated with the coating C, or it
comprises a surface area 1004, 1006 with a coating which is semitransparent to the
IR radiation, both for coupling in an IR radiation into the body MB
k. Preferably the coating comprises a metal. In a further embodiment of the mirror
the surface area 1004, 1006 is arranged on the side of the mirror body MB
k on which the reflective surface MS
k is arranged. Alternative or in addition the surface area 1004, 1006 surrounds the
reflective surface MS
k. In a further embodiment of the mirror according to the invention the surface area
1004, 1006 comprises a surface roughness to scatter an IR radiation into the body,
or the surface area comprises a diffractive structure to distribute an IR radiation
within the body MB
k by diffraction.
[0129] Fig. 12c schematically shows a further embodiment of the present invention in which
a reflective optical element or a mirror M
k, 421 is at least partly coated with a coating C2 on its surface to make the mirror
heatable. In accordance with this embodiment the coating C2 differ from the reflective
surface MS
k, 450 which may comprise also a coating in the form of a multilayer coating to reflect
the EUV light 1000. The coating C2 is selected such that it will have a certain electrical
resistance why it is called resistive coating C2. If in the resistive coating C2 an
electrical current is generated then energy is produced which is transferred as a
thermal energy to the reflective element or mirror M
k which heats up. In this way the temperature of the reflective element or mirror M
k, 421 can be controlled. In this embodiment the heater or tempering means 300 comprises
the resistive coating C2 and a voltage source VS which is connected to the coating
C2. According to this embodiment of the invention the resistive coating C2 may cover
the surface of the body M
k. Preferably there is no resistive coating C2 between the reflective surface MS
k, 450 and the body MB
k. Alternative, only a part or several parts of the surface of the body are coated
with the resistive coating C2. These parts are selected such that a homogenous temperature
distribution in the body and/or on the reflective surface can be achieved. This will
minimize the aberration of the reflective element or of the mirror as in the embodiments
described above. The electrical current in the resistive coating C2 can be generated
by an electrical voltage. For this reason a voltage source VS is connected to the
resistive coating C2 of the optical element M
k, 421. This can be done by cable 1008. Alternative or in addition the voltage source
VS is mounted on the body as shown by numeral 1010. If the voltage source is mounted
on the body MB
k there is also no mechanical connection of the heater or tempering means 300, which
is formed by the coating C2, to a support structure as it is if a cable or wires 1008
are used. Advantageously then there will be no forces or moments transferred from
the cable or the wires to the mirror or reflective optical element M
k, 421.
[0130] In further embodiments of the present invention in accordance to an embodiment as
described in Fig. 12c the reflective element or mirror of Fig. 12c can be used together
with the tempering means or heater 300 of the embodiment of Fig. 10 and/or with the
cooler 350 as described. In addition or as an alternative, also the pressure control
as described in connection with Fig. 11 can be used together with the embodiments
of Fig. 12c. In addition the embodiments of Fig. 12b and 12c may be combined, e.g.
by using the coating C for the reflection of IR light and as a resistive coating C2.
As an alternative the IR reflection coating C (of Fig. 12b) may be covered with a
resistive coating C2 which is heated by a voltage source VR as described in Fig. 12c.
Again, all these embodiments advantageously can be used in an EUV projection lens,
especially in one as described above in accordance to this invention, preferably in
the first, second and third to sixth projection lens according to this invention to
reduce thermal induced optical aberration.
[0131] Due to the advantages which are described in connection with the embodiments of a
projection lens with a mirror or reflective optical element as described in connection
with Fig. 12c, the present invention also relates to a
seventh projection lens and to a mirror used therein.
[0132] The mirror according to the present invention in connection with Fig. 12c comprises
a body MB
k and a reflective surface MS
k,. Further, the mirror comprises a material with a temperature dependent coefficient
of thermal expansion which is zero at a zero cross temperature T
0k, and the body MB
k is at least partly coated with a resistive coating C2, wherein the resistive coating
C2 has an electrical resistance suitable to heat the body by electrical resistive
heating. Further, the mirror is adapted for a projection lens of an EUV-lithographic
projection exposure system for projecting an object field on a reticle onto an image
field on a substrate if the projection lens is exposed with an exposure power of EUV
light with a wavelength in a wavelength range of less than 50 nm. Preferably the resistive
heating is between 0,01 W and 1 W. Further, the coating C2 is connected to a voltage
source VS. The voltage source preferably is attached to the mirror body MB
k, or the voltage source is electrically connected to the mirror body MB
k by a wire 1008.
[0133] In a further embodiment of the mirror as described in connection with Fig. 12c the
coating C2 of the mirror covers the mirror body MB
k except in the area of the reflective surface MS
k. Further, advantageously the body MB
k of the optical element M
k is semitransparent to an IR radiation and the resistive coating C2 is coated on a
reflective coating C coated on or on almost the entire surface of the body MB
k,. Thus a mirror with the features as described in connection with Fig. 12b can be
achieved. For this reason, preferably the reflective coating C reflects IR radiation
inside the body MB
k. In a further preferred embodiment of the mirror the mirror body MB
k comprises a surface area 1004, 1006 which is not coated with the coatings C and C2,
or it comprises a surface area 1004, 1006 with a coating which is semitransparent
to the IR radiation. These embodiments of the mirror have the advantage that an IR
radiation can be coupled into the mirror body MB
k at these surface areas 1004, 1006. The surface area 1004, 1006 is preferably arranged
on the side of the body MB
k with the reflective surface MS
k. and optionally the surface area 1004, 1006 surrounds the reflective surface MS
k.
[0134] In a further preferred embodiment of the mirror as described in connection with Fig.
12c the surface area 1004, 1006 comprises a surface roughness to scatter an IR radiation
into the body, or the surface area comprises a diffractive structure to distribute
an IR radiation within the body MB
k by diffraction. Further, the resistive coating C2 preferably comprises a metal and
also preferably the reflective and the resistive coating C, C2 comprise the same metal.
[0135] As mentioned above the present invention also relates to a seventh projection lens
to make use of the advantages as described in connection with Fig. 12c. The seventh
projection lens of an EUV-lithographic projection exposure system comprises a plurality
of reflective optical elements M
i which comprises a body MB
i and a reflective surface MS
i for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm. The EUV light is reflected from the reticle
while the reticle is illuminated by an illumination system of the EUV-lithographic
projection exposure system. In addition at least one reflective optical element M
k comprises the features of the above described embodiments of the mirror of the present
invention in connection with Fig. 12c. Further, the optical element M
k is optionally connected to an actuator for its translational movement. In a further
embodiment the seventh projection lens comprises a cooler 350 which is located on
a side of the body MB
k of the at least one optical element M
k, wherein the side is opposite to its reflective surface MS
k. Optionally a distance of the cooler 350 to the at least one reflective optical element
M
k is adjustable for the control of the heat transfer between these elements.
[0136] A further embodiment of the seventh projection lens according to this invention comprises
a pressure control system for the control of the pressure Δp within a surrounding
of the at least one reflective optical element M
k, which comprises the features of the above described embodiments of the mirror of
the present invention in connection with Fig. 12c. Further, the pressure control system
optionally comprises a gas inlet and/or a gas outlet nearby the at least one optical
element M
k.
[0137] In a further embodiment of the seventh projection lens , the projection lens heats
up without heating the resistive coating C2 which is on the body MB
k, if the reflective surface MS
k is exposed with EUV light. The EUV light is reflected by the illuminated reticle
and comprises a spatial distribution of angular, polarization and intensity in accordance
with an illumination setting, resulting in a temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) of the body MB
k relative to a reference temperature T
Ref. The temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) comprises an average and maximum temperature ΔT
kav and ΔT
kmax. Further, the zero cross temperature T
0k of the mirror body MB
k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature ΔT
kav + T
ref or ΔT
kmax + T
Ref, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) or T
0k > max(T
Ref, ΔT
kmax + T
Ref). Further also in the seventh projection lens any manufacturing tolerances of the
zero cross temperature may be considered. In such an embodiment of the seventh projection
lens the material with the zero cross temperature T
0k varies regarding its real value of the zero cross temperature due to manufacturing,
which results in a manufacturing tolerance ΔT
0k such that the real value is within the interval T
0k ± ΔT
0k,. In such a case the zero cross temperatures T
0k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature (ΔT
kav + T
Ref or ΔT
kmax + T
Ref). This maximum is additionally increased by the absolute value of the manufacturing
tolerance ΔT
0k, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) + |ΔT
0k|, T
0k > max(T
Ref, ΔT
kmax + T
Ref) + |ΔT
0k|.
[0138] In a preferred embodiment of the seventh projection lens (and its various embodiments)
the temperature T
k of the optical element M
k is controlled to its value by heating the resistive coating C2 with a first electrical
power of the voltage source at a time before the projection lens is subjected to the
exposure power of the EUV light. Further, during the time when subjecting the projection
lens to the exposure power of the EUV light the electrical power for heating the resistive
coating C2 preferably is less than the first electrical power.
Fig. 12d schematically shows a further embodiment of the present invention in which
a reflective optical element or a mirror M
k, 421 is at least partly heated by a multi-zone wire grid 1050 which is arranged nearby
the reflective surface MS
k. Such a reflective element or mirror can be manufactured with a process which comprises
the following essential steps:
- 1. Preferably as a body material MBk a material with a high zero cross temperature T0k is chosen as used e.g. in at least one of the embodiments described in this description.
As an example, at least one zero cross temperature of the body material is 30°C or
above.
- 2. The wire grid 1050 is produced on the body material, e.g. by forming a thin restive
coating on the surface of the body material MBk by an electro-plating process. The resistive coating may be or may comprise Invar.
- 3. Various pattern structures 1051 are etched into the resistive coating which forms
the structure of the multi-zone wire grid 1050. This is done by application of known
lithographic methods.
- 4. The various pattern structures 1051 are electrically connected to form a multiplexable
integrated circuit.
- 5. The pattern structures 1051 which forms the electrical circuit are covered by an
insulating layer 1052 with a low CTE, like quartz, such that the integrated circuit
is fully covered.
- 6. The surface of the insulating layer 1052 is polished to the surface figure accuracy
which is required for the reflective element or mirror Mk.
- 7. The polished insulating layer 1052 is covered with a multi-layer reflective coating
1054, whereby an optional compaction layer 1053 can be between the insulating layer
1052 and the reflective coating 1054 which forms the reflective surface MSk.
[0139] In a preferred embodiment of the reflective element or mirror the area which is covered
by of the multi-zone wire grid is about 50%, even up to 95% of the area of the reflective
surface MS
k, as schematically shown in Fig. 12d. Even a higher coverage is preferred. This has
the advantage that the heat which is generated along the wires of the wire grid is
deposited on a large area of the body material.
[0140] The reflective optical element with the wire grid has the advantage that it can be
heated without any additional heater 300 as mentioned in the various embodiments above.
For example, during the start up of the EUV-lithographic projection exposure system
the optical element can be heated up to its zero cross temperature before the EUV
projection lens is exposed with the EUV projection beam. This results in the advantages
as described in connection with the above second projection lens. The main advantage
of the wire grid is that it can control the temperature very close at the reflective
surface MS
k. If the EUV projection beam has a non-uniform intensity distribution on the reflective
surface and as a consequence is heating this surface in a non-uniform way than the
wire grid will be controlled e.g. by the control system 200 such to reduce the heating
power at locations with large EUV intensity or large EUV absorption, and it will increase
the heating power at locations with low or zero EUV absorption. With such a regulation
an almost constant temperature profile across the reflective surface of the mirror
or reflective optical element can be achieved which results in almost no thermal induced
aberration.
[0141] Further, the wire grid can also be used to measure the temperature with a spatial
resolution which is defined by the grid structure. For the temperature measurement
the electrical resistance of the wires is measured which is related to the temperature.
[0142] Further, the optical element with the wire grid can be used with other heating and
tempering concepts as described herein. For example, the optical element with the
wire grid can be combined with a heater and cooler as described with Fig. 10. In this
case the wire grid can be used to just control very small temperature variations nearby
the reflective surface MS
k. Further, the heater 300 of the embodiment as shown in Fig. 10 may be controlled
or partially controlled by the wire grid resistance values.
[0143] An additional advantage of such a combined system is that the temperature control
system can be simpler, because no feed-forward control is necessary. This is because
the surface temperature of the reflective surface can be adjusted very quick with
the wire grid heater if this heater just controls a small temperature range around
the zero cross temperature of the mirror material and if other heaters or heating
concepts heat the mirror close to this zero cross temperature.
[0144] Due to the advantages which are described in connection with the embodiments of a
projection lens with a mirror or reflective optical element as described in connection
with Fig. 12d, the present invention also relates to a
eight projection lens and to a mirror with the described wire grid 1050 used therein.
[0145] As mentioned, the present invention relates to a mirror with a wire grid, the mirror
comprises a body MB
k and a reflective surface MS
k. Further, the body MB
k comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a zero cross temperature T
0k, wherein at least a part of the surface of the body MB
k comprises a wire grid 1050 for electrically resistive heating of the body MB
k. In addition the mirror is preferably adapted for usage in a projection lens of an
EUV-lithographic projection exposure system for projecting an object field on a reticle
onto an image field on a substrate if the projection lens is exposed with an exposure
power of EUV light with a wavelength in a wavelength range of less than 50 nm. Further,
the wire grid 1050 of the mirror is formed by a resistive coating with a coating material
and the coating material is selected from the group consisting of: metal, semiconductor
material, a material comprising carbon and invar.
[0146] Preferably the wire grid 1050 of the mirror comprises a pattern structure 1051 with
at least N > 1 electrical circuits. Preferably the pattern structure 1051 comprises
at least N+1 electrical connectors to connect the N electrical circuits to an electrical
power source to subject the N electrical circuits with an electrical power. Preferably
the N electrical circuits can be independently controlled from each other regarding
its electrical power to which they are subjected. Further, the heating power of the
wire grid 1050 is between 0,01 W and 5 W, preferably between 0,01 W and 1 W. The mirror
with the wire grid 1050 is connected to at least one electrical power source. The
electrical power source may be attached to the mirror body MB
k or the electrical power source is electrically connecting the mirror body MB
k e.g. by a wire or by wires. Further the electrical power source comprises at least
two voltage and/or current sources. In addition the electrical power source may comprise
a multiplexer circuit. With the multiplexer circuit the N electrical circuits of the
wire grid are sequentially subjected with electrical power from the power source.
Further, the mirror with the wire grid in accordance with the present invention comprises
an insulating layer 1052, wherein the pattern structure 1051 of the wire grid 1050
is covered by the insulating layer 1052 The insulating layer 1052 comprises a low
CTE material. Further, the insulating layer 1052 is polished such to having surface
figure data within an accuracy of ± 3 nm RMS as required for the reflective surface
MS
k of the mirror. To improve the reflectivity of the mirror for EUV light, the reflective
surface MS
k of the mirror with the wire grid 1050 comprises a multilayer stack 1054 which is
arranged above the insulating layer 1052, or which is arranged above a compaction
layer 1053. The compaction layer 1053 is arranged above the insulating layer 1052.
Preferably the wire grid 1050 of the mirror covers more than 50% of the area of the
reflective surface MS
k.
[0147] Further, the above described mirror with the wire grid 1050 can be modified such
that the mirror comprises also features of the mirrors as described in connection
with Fig. 12b and Fig. 12c. As an example, the body MB
k of the mirror is at least partly coated with a resistive coating C2 except in the
area of the reflective surface MS
k. The resistive coating C2 has an electrical resistance suitable to heat the mirror
body MB
k by electrical resistive heating. Alternative or in addition the body MB
k of the optical element M
k is semitransparent to an IR radiation. If so, advantageously the body MB
k of the mirror comprising a reflective coating C coated on or on almost the entire
surface of the body MB
k, wherein the reflective coating C reflects IR radiation inside the body MB
k. In a further embodiment of the mirror with the wire grid in accordance to this invention
a resistive coating C2 is on the reflective coating C. In this case the mirror can
be heated by IR radiation (due to the coating C) and/or by resistive heating due to
the coating C2, wherein the area close to the reflective surface MS
k is headed with the wire grid 1051. For the heating of the mirror with IR radiation
the mirror advantageously comprises a surface area 1004, 1006 which is not coated
with the reflective coating C and the resistive coating C2, or it comprises a surface
area 1004, 1006 with a coating which is semitransparent to the IR radiation. This
surface area 1004, 1006 advantageously can be used for the coupling in of an IR radiation
into the body MB
k, wherein the IR radiation contributes to the heating of the mirror. Preferably the
mirror with the reflective coating C or the resistive coating C2 comprises a metal
in the coating layer, preferably the metal is the same for the reflective and the
resistive coating C, C2, if both coatings are applied. Further, the surface area 1004,
1006, for coupling in an IR radiation into the body MB
k, is arranged on the side of the body MB
k with the reflective surface MS
k, or on a the surface area 1004, 1006 which surrounds the reflective surface MS
k. Such a surface area 1004, 1006 advantageously may comprise a surface roughness to
scatter the IR radiation into the body, or the surface area 1004, 1006 may comprises
a diffractive structure to distribute the IR radiation within the body MB
k by diffraction.
[0148] As mentioned above the present invention also relates to a eighth projection lens
to make use of the advantages as described in connection with Fig. 12d and the advantages
of the mirror which comprises a wire grid 1050 and its various embodiments as discussed
above.
[0149] In a first embodiment of the eighth projection lens of an EUV-lithographic projection
exposure system, comprises a plurality of reflective optical elements M
i. Each reflective optical elements M
i comprises a body MB
i and a reflective surface MS
i for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm. The EUV light is reflected from the reticle
while the reticle is illuminated by an illumination system of the EUV-lithographic
projection exposure system. Further, the eighth projection lens comprises at least
one reflective optical element M
k which comprises the features of the mirror comprising the wire grid 1050 in accordance
to one of the above described embodiments of this mirror. Further, since one reflective
optical element M
k with the features of the mirror with the wire grid 1050 is heatable, it is advantageous
to connect the optical element M
k to an actuator for its translational movement. Further, in an embodiment of the eighth
projection lens the lens comprises a cooler 350 or a first tempering element 300 which
is located on a side of the body MB
k of the at least one optical element M
k which is opposite to its reflective surface MS
k. Optionally a distance of the cooler 350 or the first tempering element 300 to the
at least one reflective optical element M
k is adjustable for the control of the heat transfer between these elements. In a further
embodiment of the eighth projection lens the lens comprises a pressure control system
for the control of the pressure Δp within a surrounding of the at least one reflective
optical element M
k, Preferably the pressure control system comprises a gas inlet and/or a gas outlet
nearby the at least one optical element M
k.
[0150] In a further embodiment the eighth projection lens comprises a material selection
such that without heating the wire grid 1050 on the body MB
k, the exposure of the reflective surface MS
k with EUV light, which is reflected by the illuminated reticle and which comprises
a spatial distribution of angular, polarization and intensity in accordance with an
illumination setting, results in a temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) of the body MB
k with the temperature T
k(x,y,z) relative to a reference temperature T
Ref. The temperature distribution ΔT
k(x,y,z) = (T
k(x,y,z)-T
Ref) comprises an average and maximum temperature ΔT
kav and ΔT
kmax. Further the zero cross temperature T
0k of the body MB
k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature (ΔT
kav + T
ref or ΔT
kmax + T
Ref), expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) or T
0k > max(T
Ref, ΔT
kmax + T
Ref).
[0151] Usually the material with the zero cross temperature T
0k varies regarding its real value of the zero cross temperature due to manufacturing
issues. For this reason a further preferred embodiment of the eighth projection lens
considers that the material with the zero cross temperature T
0k varies regarding its real value of the zero cross temperature due to manufacturing,
which result in a manufacturing tolerance ΔT
0k such that the real value is within the interval T
0k ± ΔT
0k. In this embodiment the zero cross temperatures T
0k is selected higher than the maximum of the reference temperature T
Ref and the respective average or maximum temperature based on the spatial temperature
distribution ΔT
k(x,y,z) added by the reference temperature (ΔT
kav + T
Ref or ΔT
kmax + T
Ref), and the maximum is further increased by the absolute value of the manufacturing
tolerance ΔT
0k, expressed as T
0k > max(T
Ref, ΔT
kav + T
Ref) + |ΔT0
k|, T
0k > max(T
Ref, ΔT
kmax + T
Ref) + |ΔT
0k|.
[0152] In a further embodiment of the eighth projection lens the temperature T
k of the optical element M
k is controlled to its value by heating the wire grid 1050 with a first electrical
power of the electrical power source at a time before the projection lens is subjected
to the exposure power of the EUV light. Optionally, during the time when subjecting
the projection lens to the exposure power of the EUV light, the electrical power for
heating the wire grid 1050 is selected less than the first electrical power. Further,
the eighth projection lens may comprise a controller for controlling the electrical
power to which the wire grid 1050 is subjected, or for determining a resistance value
of the wire grid 1050, or a resistance value of at least one of the electrical circuits
of the pattern structure 1051. Further, optionally the controller controls the temperature
of the first tempering element 300 or the cooler 350. Further optionally the controller
controls a distance of the first tempering element 350 or the cooler 300 to the at
least one reflective optical element M
k, or the controller controls the pressure Δp within the surrounding of the optical
element M
k. In general the control is based on a parameter selected from the group consisting
of: temperature, resistance value of the wire grid 1050 or the resistance value of
at least one electrical circuit of the pattern structure 1051 of the wire grid 1050,
time, a parameter which directly or indirectly influence the temperature of the optical
element M
k, an illumination setting, a change of the exposure power of the EUV light, a change
of the reticle, thermally or mechanically induced optical aberration data of the optical
element M
k or the projection lens and an output parameter from a model. Further, the controller
preferably controls the temperature of the reflective surface MS
k, or the body MB
k of the mirror M
k to the zero cross temperature T
0k. In a further embodiment of the eighth projection lens the zero cross temperature
T
0k is selected lower than a reference temperature T
Ref, or it is selected such that it is at least 6 K higher than a reference temperature
T
Ref.
[0153] Fig. 13 schematically shows several further embodiments of heaters or tempering means
300 in relation with a reflective element or mirror M
k, 421 in accordance with the present invention. Also with these embodiments the temperature
of the reflective element or mirror M
k, 421 can be controlled to an operation temperature, averaged temperature or zero
cross temperature T
avk, T
0k according to the above teachings, especially to reduce any optical aberration caused
by thermal effects. The various embodiments of the heater or tempering means 300 which
will be described below can be used alone or in any combination to control the mentioned
temperatures or the aberration of the reflective optical element or mirror.
[0154] The mirror e.g. 421 (like the ones shown in Fig. 4 and Fig. 5) or a reflective element
M
k is mounted to a support element 480 which is connected to a housing structure 481.
The mounting elements and support means which support or suspend the mirror or the
reflective optical element are not shown. These can be made as e.g. described in Fig.
4 with the reference numerals 451, 461, 471. Further, as described in the embodiment
of Fig. 10 and Fig. 11 a cooler 350 can be used as an option to protect the support
element 480 and/or the housing structure 481 (which can be temperature sensitive elements).
As a further option also the pressure Δp of the surrounding of the mirror 421 or the
reflective optical element may be controlled to adjust the thermal resistance of the
gas, as described with Fig. 11. If the body MB
k of the reflective element or mirror M
k, 421 comprises a material with a temperature dependent CTE(T) which comprises at
least one zero cross temperature To, like e.g. Zerodur® or ULE®, and if this material
is transparent to light of a certain wavelength like IR light, then the body may be
heated with such light as it was described in connection with Fig. 12a and Fig. 12b.
This kind of heating has the advantage that the heat is not only deposited on the
surface of the body MB
k but it is also deposited inside the body.
[0155] As sources for IR light, e.g. light emitting diodes (LEDs) 1302 may be used. The
usage of LEDs have the advantage that they easily can be arranged about side by side
in at least one dimension, to form an array-like arrangement as it was already mention
in the context of the Peltier elements of Fig. 10. Further, a suitable optical arrangement
can be used to configure the IR radiation which is emitted from the LEDs in such a
way that it can be coupled into the reflective element or the mirror M
k, 421 under various conditions. As an example the optical arrangement 1304 is such
that the IR light from LED is collected and made about parallel. This has the advantage
that a defined area of the surface of the body MB
k is illuminated with IR light. Optionally this surface area can be adjusted in diameter,
depending on the number of LEDs which are in operation. If such LEDs with such an
optical arrangement are forming a grid to illuminate the body MB
k in a grid- or matrix-like form. The grid-like form has the advantage that IR energy
is deposited as a function of the grid-coordinates which result in a much defined
spatial temperature distribution T(x,y) as a function of x and y. As a further option,
the optical arrangement 1306 of the IR source, e.g. the lenses in front of the LEDs,
may be adjustable to generate a focus length and/or vary the focus length 1307. With
a focused IR light the body can be heated at a very local point inside. With this
feature the spatial temperature distribution inside the body can be adjusted in x-,
y- and z-direction. If the direction of the IR light can be also adjusted by tilting
the IR beam around at least one axis, preferably around the x- and the y-axis, then
IR light of several IR beams can be focused in a narrow region within the body MB
k. This advantageously can be used to homogenize a temperature distribution T(x,y,z)
of the body which results from e.g. a certain reticle or illumination setting. In
a preferred embodiment the focus length 1309 is adjusted by the optical arrangement
1308 in such a way that it is very close to the reflective surface MS
k. In addition an absorption layer (not shown) may be arranged below the reflective
surface which absorbs the IR light. In this case the energy of the IR light is deposited
very close to the reflective surface MS
k.
[0156] As an alternative to the above described optical arrangement arrangements optical
fibers 1310 may be used to transfer the IR light from the source (e.g. IR LEDs or
an IR Laser) to close to the surface of the body MB
k. By the usage of the fibers the IR light of one IR source can be distributed also
in a grid-like manner. A further alternative is to use a light guiding rod 1314 to
transfer the IR light from the IR source to the body.
[0157] As a further alternative an IR light source 1312 (e.g. IR LEDs, IR-Laser) is used
with a mirror 1313 which reflects the IR light onto the surface of the body MB
k. Preferably the mirror can be tilted around at least one axis, better about two axes
like the x- and the y-axis. With such an embodiment the IR light can be distributed
over the body. This can be done e.g. by a scanning or by a raster process.
[0158] In addition the body MB
k of the reflective element or the mirror itself may comprise recesses 1315 in which
the IR light is coupled in. In general the surfaces or surface areas in which the
IR light is coupled into the body may be or may comprise prepared surface areas with
e.g. a defined surface roughness or a diffractive structure on it. Further, the recesses
may comprise surface forms like spheres to improve the incidence of the IR radiation
into the body. Instead of recesses also protrusions or projections of the body material
can be chosen, which all may comprise a surface curvature, to achieve a determined
spatial distribution of the IR radiation within the body M
k.
[0159] For the embodiments of Fig. 13 also a reflective coating on the mirror body may be
used to increase the absorbed IR power. For this reason also the features of the embodiment
of Fig. 12b can be applied. Further, the heater 300 of the embodiments in accordance
of Fig. 13 can be integrated into the cooler 350. In addition, the wavelength of the
IR radiation can be controlled to control the amount of absorption within a defined
thickness of the body material. For Zerodur® the wavelength may vary from about 400
nm to about 800 nm. As it can be seen from Fig. 12a, in this wavelength range the
absorption strongly depends on the used wavelength.
[0160] Due to the instantaneous deposition of the IR power inside the body of the reflective
element or mirror in a spatially controlled manner, the heater or tempering means
300, as described in connection with Fig. 13, are suitable to control the operation
temperature of the reflective element or mirror inside a projection lens in such a
way that the thermal induced aberration is minimized in the steady state of the lens
and during the warm-up time of the mirror. This time can be significantly reduced
due to the instantaneous heating effect of the IR heating.
[0161] Further, with the IR heating of the body MB
k of the k-th reflective optical element or the mirror M
k of an EUV projection lens, as shown in connection with Fig. 12b and Fig. 13 as an
example, it is possible to heat this body to the at least one of its zero cross temperatures
very fast. Further, with such a heating the spatial temperature distribution within
the body and such along its reflective surface MS
k can be controlled in at least two dimensions, preferably in all three spatial dimensions.
This means that the temperature is controllable as a function of the x-, y- and z-coordinate
of the body MB
k. Regarding the control now reference is made again to Fig. 6. With such heaters as
designated with 630 in Fig. 6 an EUV projection lens 20 can comprise at least one
reflective element or mirror M
k, like mirror 26, which comprises a body MB
k with comprises a material with a temperature dependent CTE(T) which has at least
one zero cross temperature T
0k. This zero cross temperature T
0k is selected such that it is higher than the expected average temperature ΔT
avk + T
Ref of the element or mirror M
k if the projection lens 20 is exposed with the maximum EUV exposure power, coming
from the reticle M. The zero cross temperature is even selected higher that the respective
maximum temperature of all the expected temperature distributions T(x,y,z) which may
occur during the exposure with the EUV exposure power (see for example Fig, 7). These
average and maximum temperatures ΔT
avk , ΔT
kmax also consider potential variations regarding the reticle and regarding the illumination
setting. Further, also any variations of the zero cross temperatures, caused by the
manufacturing like manufacturing tolerances ΔT
0k, may be considered in a way that such tolerances are added to the these average or
maximum temperatures ΔT
avk, ΔT
kmax before the material selection. Then a material is selected such that its zero cross
temperature is even higher than this temperature, expressed as T
0k > ΔT
kmax + T
Ref + |ΔT
ok| or T
ok > ΔT
avk + T
Ref + |ΔT
0k|. With the application of the mentioned IR heaters (or the other heaters described
in this specification) it is always possible to heat the element or mirror M
k to the real zero cross temperature. A control unit 620 (Fig. 6) controls the temperature
of this element M
k (like mirror 26) preferably such that the thermal induced aberration or imaging errors
622 of the projection lens (or the element or mirror M
k) becomes to a minimum during the exposure of the lens 20 with the EUV exposure beam
4 which propagates from the reticle M to the wafer W. As an alternative the control
unit 620 controls the temperature such that the spatial temperature distribution 621
on the reflective element or mirror M
k, 26 becomes homogenous, preferably that this temperature achieves the zero cross
temperature T
0k.
[0162] Further, if the zero cross temperature is selected as described above like T
0k > ΔT
kmax + T
Ref + |ΔT
0k| or T
0k > ΔT
avk + T
Ref + |ΔT
0k| then preferably the body MB
k and the reflective surface for the EUV light MS
k is manufactured such that the surface shape or figure achieves the specified accuracy
at the zero cross temperature T
0k. In this case the reflective element or mirror M
k is hated with the mentioned IR heaters 630, or other heaters as already have been
described herein, to the zero cross temperature. Preferably this heating is done before
the projection lens 20 is subjected to the EUV exposure power. During the exposure
of the projection lens 20 with EUV light then the reflective optical element or mirror
M
k is heated in addition by the absorbed EUV light. The heater 630 then is controlled
by the control unit 620 such that the spatial temperature distribution of the reflective
element or mirror M
k remains almost in the same condition as before the EUV light is switched on. Preferably
this condition is a constant temperature of the element or mirror M
k, 26. As already mentioned, it is not necessary to control the temperature distribution
621 of the element M
k, 26 itself, alternative or in addition the aberration 622 can be used as a control
parameter, and then the heater 630 is controlled such that the aberration 622 is minimized.
To measure the temperature of the element M
k or mirror 26, especially the spatial temperature distribution, or a parameter or
parameters which are representative for it, an infrared camera can be used, since
the temperature differences due to the absorption of EUV light are in the range of
about 1 K up to about 20 K, depending on the mirror 21, 22, 23, 24, 25, 26 of the
lens 20 (see. e.g. Fig. 3), the used reticle or mask, the power of the EUV light and
the illumination setting. Due to this relatively high temperature difference the sensitivity
requirements of the IR camera are not too high.
[0163] Alternative or in addition to the measurement of the temperature or the temperature
distribution of the optical element M
k or mirror 26, or its aberration 622, as a control parameter also the deformation
of the optical element M
k or the mirror 26 (anyone of the mirrors 21, 22, 23, 24, 25, 26 within the lens 20)
or a parameter related to the deformation may be used, to control the heater 630,
especially a heater 630, 300 as described herein. For a deformation measurement, as
an example, an interferometer and/or an encoder system can be used to determine any
deformation of the optical element or mirror.
[0164] In a further embodiment of the invention, the temperature data (especially the temperature
distribution data) and/or the deformation data which result from measurements as described
above are used for the calculation of an expected aberration of the optical element
or mirror or the lens 20. Then the lens 20 and/or the optical element M
k or the mirror 21, 22, 23, 24, 25, 26 is controlled by at least one heater 630, 300
in such a way that the aberration will be reduced. For such calculations a model is
applied why the aberration of the lens 20 is minimized by model based control. The
model for the control of the lens 20 may use additional input parameters which are
measured in addition to the temperature and/or deformation data of a given preselected
mirror or optical element. Such input parameters are e.g. the used reticle or mask,
the power of the EUV light, the illumination setting, a gas pressure nearby the optical
element or mirror or inside the lens 20, the time for which the lens 20 is exposed
by EUV light or any change in position (like e.g. z-position) of a reflective optical
element like a mirror 21, 22, 23, 24, 25, or 26 of lens 20. As an output parameter
the model may control any heater 630, 300, any position of a reflective optical element
like a mirror 21, 22, 23, 24, 25, or 26, the power of the EUV projection light, the
illumination setting with which the reticle is illuminated, the gas pressure nearby
the optical element or mirror or the gas pressure inside the lens 20 or any actuator
which deforms the reflective surface of a mirror 21, 22, 23, 24, 25 or 26 of the lens
20 in a controlled way to reduce the optical aberration. The output parameter or the
output parameters are correlated to the input parameter or the input parameters by
the model transfer-function. Further, the input parameters of the model may be used
for model calibration such that the model is adjusted regarding its transfer-function,
meaning that the transfer-function itself depend on the values of the input parameters
and/or the output parameters.
[0165] Further, in an embodiment of the present invention the temperature data of at least
one optical element M
k, like a mirror 21, 22, 23, 24, 25, 26 of the lens 20 are accumulated in time. This
results in a parameter which represents a measure of the thermal load of the optical
element or mirror, which could be even with spatial resolution. Such a thermal load
parameter can be used for maintenance control of the lens 20 or the EUV lithographic
exposure system. As an example, any degradation of the mirror due to EUV light, like
a degradation of the reflective multilayer stack or any compaction effects of the
used substrate material, forming the mirror body, may be estimated. Further, the illuminated
masks or the used illumination settings may be selected such that the spatially resolved
thermal load of the mirror 21, 22, 23, 24, 25, 26 results in a long life time of the
projection lens 20, to reduce maintenance costs.
[0166] The present invention comprises the aspects defined in the following clauses, which
form part of the present description but are not claims, in accordance with decision
J15/88 of the European Patent Office legal board of appeal.
- 1.A projection lens of an EUV-lithographic projection exposure system, comprising
at least two reflective optical elements Mi, each
- comprising a body MBi and a reflective surface MSi for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with the exposure power of the EUV light, being reflected
from the reticle when illuminated by an illumination system of the EUV-lithographic
projection exposure system, wherein
- the bodies MBm, MBn of at least two reflective optical elements comprise a material with a temperature
dependent coefficient of thermal expansion which is zero at respective zero cross
temperatures T0m, T0n, wherein
- the absolute value of the difference between the zero cross temperatures T0m, T0n is more than 6K, expresses as abs(T0m - T0n)> 6K, and wherein
- the projection lens is designed to be exposed with an exposure power of more than
8W of EUV light with a wavelength in a wavelength range of less than 50 nm.
- 2.The projection lens according to clause 1, comprising
- four or six reflective optical elements Mi,
- the projection lens being designed to be exposed with an exposure power of more than
10W and
- the absolute value of the difference between the zero cross temperatures T0m, T0n is more than 8K, expresses as abs(T0m - T0n)> 8K.
- 3.The projection lens according to clause 1 or 2, comprising a
- support structure for passively or actively supporting the reflective optical elements
Mi, wherein the temperature of at least a part of the support structure is at a reference
temperature TRef,
- a heater for heating at least one of the bodies MBn, MBm comprising the material with the temperature dependent coefficient of thermal expansion
which is zero at respective zero cross temperatures T0m, T0n, and
- a temperature control system for controlling the temperature of the at least one heatable
body MBn , MBm to a temperature Tk.
- 4.The projection lens according to clause 3, wherein
- without operation of the heater the exposure of the reflective surfaces MSm and MSn of the bodies MBn, MBm with EUV light, being reflected by the illuminated reticle and comprising a spatial
distribution of angular, polarization and intensity in accordance with an illumination
setting, resulting in temperature distributions ΔTn,(x,y,z) = (Tn(x,y,z)-TRef), ΔTm(x,y,z) = (Tm(x,y,z)-TRef) of the bodies MBn, MBm relative to the reference temperature TRef with respective average and maximum temperatures ΔTnav, ΔTmav and ΔTnmax and ΔTmmax; and wherein
- at least one zero cross temperatures T0m, T0n is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature ΔTmav + Tref or ΔTmmax + Tref, ΔTnav + Tref or ΔTnmax + Tref, based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), expressed as T0m > max(TRef, ΔTmav + Tref), T0m > max(TRef, ΔTmmax + Tref) or T0n > max(TRef, ΔTnav + TRef), T0n > max(TRef, ΔTnmax + Tref).
- 5.The projection lens according to clause 4, wherein
- the materials comprising the zero cross temperatures T0m, T0n vary regarding their real value of the zero cross temperature due to manufacturing,
resulting in respective manufacturing tolerances ΔT0m, ΔT0n such that the respective real values of the zero cross temperatures are within the
intervals T0m ± ΔT0m and T0n ± ΔT0n, and wherein
- at least one zero cross temperatures T0m, T0n is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature ΔTmav + TRef or ΔTmmax + TRef, ΔTnav + TRef or ΔTnmax + TRef, based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), increased by the absolute value of the respective manufacturing tolerances
ΔT0m, ΔT0n, expressed as T0m > max(TRef, ΔTmav + TRef) + |ΔT0m|, T0m > max(TRef, ΔTmmax + TRef) + |ΔT0m| or T0n > max(TRef, ΔTnav + TRef) + |ΔT0n|, T0n > max(TRef, ΔTnmax + TRef) + |ΔT0n|.
- 6.The projection lens according to clause 4 or 5, wherein
- the temperature Tk of the at least one heated body MBn, MBm is within an interval of ± 5K, better ± 2K centered around the respective zero cross
temperature T0m, T0n.
- 7.The projection lens according to one of the clauses 3 to 6, wherein
- at a time before the projection lens is exposed with the exposure power of the EUV
light the temperature Tk of the at least one heated body MBn, MBm is controlled to its value by heating the heater with a first heating power.
- 8.The projection lens according to clause 7, wherein
- at the time while exposing the projection lens with the exposure power of the EUV
light the heating power of the heater is lower than the first heating power.
- 9.The projection lens according to clause 7 or 8, wherein
- the temperature control system controls the temperature Tk such that the heating power of the heater, heating the at least one body MBn, MBm, and the exposure power of the EUV light absorbed by the at least one heated body
MBn, MBm is constant in time.
- 10.The projection lens according to one of the clauses 1 to 9 with 4 or 6 reflective
optical elements in form of mirrors.
- 11. The projection lens according to one of the clauses 3 to 10, wherein the at least
one heated body MBn, MBm is connected to an actuator for translational movement of the body.
- 12.The projection lens according to one of the clauses 3 to 11. wherein the heater
for heating the at least one of the bodies MBn, MBm comprises heating elements selected from the group consisting of IR light emitting
diodes, Peltier elements, optical fibers, light guide rods and IR lasers.
- 13. The projection lens according to clause 12, wherein the heating elements are arranged
in one dimension or in two dimensions at predefined spatial coordinates, forming a
grid structure.
- 14.The projection lens according to clause 12 or 13, wherein the heating elements
emitting or guiding IR radiation comprising an optical arrangement to configure the
IR radiation, the optical arrangement comprises arrangement elements selected from
the group consisting of collimator, focusing lens, adjustable lens, mirror and diffractive
optical element, wherein the arrangement elements may be tiltable around at least
on axis.
- 15.The projection lens according to one of the clauses 12 to 14, wherein the at least
one of the bodies MBn, MBm comprises a modification in or on the mirror body, the modification is selected from
the group consisting of recess, blind hole, defined surface roughness, diffractive
structure, spherical protrusion, spherical recess and surface curvature.
- 16.An EUV-lithographic projection exposure system, comprising a projection lens according
to one of the clauses 1 to 15.
- 17.A projection lens of an EUV-lithographic projection exposure system, comprising
- at least two reflective optical elements Mi, each
- comprising a body MBi and a reflective surface MSi for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm, being reflected from the reticle when illuminated
by an illumination system of the EUV-lithographic projection exposure system, wherein
- the bodies MBm, MBn of at least two reflective optical elements comprise a material with a temperature
dependent coefficient of thermal expansion which is zero at respective zero cross
temperatures T0m, T0n and wherein the lens comprises a
- support structure for passively or actively supporting the reflective optical elements
Mi, wherein the temperature of at least a part of the support structure is at a reference
temperature TRef,
- a heater for heating at least one of the bodies MBn, MBm comprising the material with the zero cross temperatures T0m, T0n, and
- a temperature control system for controlling the temperature of the at least one heated
body MBn, MBm to a temperature Tk, wherein
- without heating the bodies MBn, MBm with the heater the exposure of the reflective surfaces MSm and MSn with the exposure power of the EUV light, being reflected by the illuminated reticle
and comprising a spatial distribution of angular, polarisation and intensity in accordance
with an illumination setting, resulting in temperature distributions ΔTn,(x,y,z) = (Tn(x,y,z)-TRef), ΔTm(x,y,z) = (Tm(x,y,z)-TRef) of the bodies MBn, MBm relative to the reference temperature TRef with respective average and maximum temperatures ΔTnav, ΔTmav and ΔTnmax and ΔTmmax; and wherein
- at least one zero cross temperatures T0m, T0n is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature added by the reference temperature
(ΔTmav + Tref or ΔTmmax + TRef, ΔTnav + TRef or ΔTnmax + TRef), based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), expressed as T0m > max(TRef, ΔTmav + TRef), T0m > max(TRef, ΔTmmax + TRef) or T0n > max(TRef, ΔTnav + TRef), T0n > max(TRef, ΔTnmax + TRef).
- 18.The projection lens of clause 17, wherein
- the materials comprising the zero cross temperatures T0m, T0n vary regarding their real value of the zero cross temperature due to manufacturing,
resulting in manufacturing tolerances ΔT0m, ΔT0n such that the respective real values of the zero cross temperatures are within the
intervals T0m ± ΔT0m and T0n ± ΔT0n , and wherein
- at least one zero cross temperatures T0m, T0n is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature ΔTmav + TRef or ΔTmmax + TRef, ΔTnav + TRef or ΔTnmax + TRef, based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), increased by the absolute value of the respective manufacturing tolerances
ΔT0m, ΔT0n, expressed as T0m > max(TRef, ΔTmav + TRef) + |ΔT0m|, T0m > max(TRef, ΔTmmax + TRef) + |ΔT0m| or T0n > max(TRef, ΔTnav TRef) + |ΔT0n|, T0n > max(TRef, ΔTnmax + TRef) + |ΔT0n|.
- 19.The projection lens of clause 17 or 18, wherein
- the absolute value of the difference between the zero cross temperatures T0m, T0n is more than 6K, expresses as abs(Tom - Ton) > 6K and wherein
- the projection lens is designed to be exposed with an exposure power of more than
8 W of EUV light with a wavelength in a wavelength range of less than 50 nm.
- 20.The projection lens of clause 19, comprising
- four or six reflective optical elements Mi,
- the projection lens is designed to be exposed with an exposure power of more than
10W of EUV light with a wavelength in a wavelength range of less than 50 nm and
- the absolute value of the difference between the zero cross temperatures T0m, T0n is more than 8 K, expresses as abs(Tom - Ton) > 8K.
- 21.The projection lens according to one of the clauses 17 to 20, wherein
- the temperature Tk of the at least one heated body MBn, MBm is within an interval of ± 5K, better ± 2K centered around the respective zero cross
temperature T0m, T0n.
- 22.The projection lens according to one of the clauses 17 to 21, wherein
- at time before the projection lens is subjected to the exposure power of the EUV light
the temperature Tk of the at least one heated body MBn, MBm is controlled to its value by heating the heater with a first heating power.
- 23.The projection lens according to clause 22, wherein
- at the time when subjecting the projection lens to the exposure power of the EUV light
the heating power of the heater is less than the first heating power.
- 24.The projection lens according to clause 22 or 23, wherein
- the temperature control system controls the temperature Tk such that the heating power of the heater, heating the at least one body MBn, MBm, and the exposure power of the EUV light absorbed by the at least one heated body
is constant in time.
- 25.The projection lens according to one of the clauses 17 to 24, wherein
- the bodies MBn and MBm with the respective zero cross temperatures T0m, T0n are made of the same material.
- 26.The projection lens according to one of the clauses 17 to 25 with 4 or 6 reflective
optical elements in form of mirrors.
- 27.The projection lens according to one of the clauses 17 to 26, wherein the at least
one heated body MBn, MBm is connected to an actuator for translational movement of the body.
- 28.The projection lens according to one of the clauses 17 to 27. wherein the heater
for heating the at least one of the bodies MBn, MBm comprises heating elements selected from the group consisting of IR light emitting
diodes, Peltier elements, optical fibers, light guide rods and IR lasers.
- 29. The projection lens according to clause 28, wherein the heating elements are arranged
in one dimension or in two dimensions at predefined spatial coordinates, forming a
grid structure.
- 30.The projection lens according to clause 28 or 29, wherein the heating elements
emitting or guiding IR radiation comprising an optical arrangement to configure the
IR radiation, the optical arrangement comprises arrangement elements selected from
the group consisting of collimator, focusing lens, adjustable lens, mirror and diffractive
optical element, wherein the arrangement elements may be tiltable around at least
on axis.
- 31.The projection lens according to one of the clauses 28 to 30, wherein the at least
one of the bodies MBn, MBm comprises a modification in or on the mirror body, the modification is selected from
the group consisting of recess, blind hole, defined surface roughness, diffractive
structure, spherical protrusion, spherical recess and surface curvature.
- 32.An EUV-lithographic projection exposure system, comprising a projection lens according
to one of the clauses 17 to 31.
- 33.A projection lens of an EUV-lithographic projection exposure system, comprising
- at least two reflective optical elements Mi, each
- comprising a body MBi and a reflective surface MSi for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm, being reflected from the reticle while illuminated
by an illumination system of an EUV-lithographic projection exposure system, wherein
- the bodies MBm, MBn of at least two reflective optical elements comprise a material with a temperature
dependent coefficient of thermal expansion which is zero at least two zero cross temperatures
T10mn and T20mn, and wherein the lens comprises a
- support structure for passively or actively supporting the reflective optical elements
Mi, wherein the temperature of at least a part of the support structure is at a reference
temperature TRef,
- at least two tempering means, preferably heaters, for independently heating and/or
cooling the at least two bodies MBn, MBm, and
- a temperature control system for independently controlling the temperature of the
at least two heated or cooled bodies MBn, MBm to respective temperatures Tkn and a Tkm, and wherein
- during exposure of the lens with the exposure power of the EUV light the temperatures
Tkn of the temperature controlled body MBn is within an interval of ± 5K, better ± 2K centered around the first zero cross temperatures
T10mn, and the temperatures Tkm of the temperature controlled body MBm is within an interval of ± 5K, better ± 2K centered around the second zero cross
temperatures T20mn.
- 34.The projection lens according to clause 33, wherein at least one of the two zero
cross temperatures T10mn and T20mn is higher that the reference temperature TRef.
- 35.The projection lens in accordance with clause 33 or 34, wherein
- without heating the bodies MBn, MBm with the heaters the exposure of the reflective surfaces MSm and MSn with the EUV light, being reflected by the illuminated reticle and comprising a spatial
distribution of angular, polarization and intensity in accordance with an illumination
setting, resulting in a temperature distributions ΔTn(x,y,z) = (Tn(x,y,z)-TRef), ΔTm(x,y,z) = (Tm(x,y,z)-TRef) of the bodies MBn, MBm relative to the reference temperature TRef with respective average and maximum temperatures ΔTnav, ΔTmav and ΔTnmax and ΔTmmax; and wherein
- at least one of the two zero cross temperatures T10mn and T20mn is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature ΔTmav + TRef or ΔTmmax + TRef, ΔTnav + TRef or ΔTnmax + TRef, based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), expressed as T10mn > max(TRef, ΔTmav + TRef), T10mn > max(TRef, ΔTmmax + TRef) or T20mn > max(TRef, ΔTnav + TRef), T20mn > max(TRef, ΔTnmax + TRef).
- 36.The projection lens according to one of the clauses 33 to 35, wherein
- the material comprising the zero cross temperatures T10mn and T20mn vary regarding their real values of these zero cross temperatures due to manufacturing,
resulting in manufacturing tolerances ΔT10mn, ΔT20mn such that the respective real values are within the intervals T10mn ± ΔT10mn and ΔT20mn ± ΔT20mn, and wherein
- at least one zero cross temperatures T10mn, T20mn is higher than the maximum of the highest reference temperature TRef and the respective average or maximum temperature ΔTmav + TRef or ΔTmmax + TRef, ΔTnav + TRef or ΔTnmax + TRef, based on the respective spatial temperature distribution ΔTm(x,y,z), ΔTn(x,y,z), increased by the absolute value of the respective manufacturing tolerances
|ΔT10mn|, |ΔT20mn|, expressed as T10mn > max(TRef, ΔTmav + TRef) + |ΔT10mn| or T10mn > max(TRef, ΔTmmax + TRef) + | ΔT10mn| or T20mn > max(TRef, ΔTnav + TRef) + |ΔT20mn| or T20mn > max(TRef, ΔTnmax + TRef) + |ΔT20mn|.
- 37.The projection lens in accordance with one of the claims 33 to 36, wherein
- at a time before the projection lens is subjected to the exposure power of the EUV
light the temperature Tkn or Tkm of the at least one heated body MBn, MBm is controlled to its value by heating the heater with a first heating power.
- 38.The projection lens in accordance with clause 37, wherein
- at the time when subjecting the projection lens to the exposure power of the EUV light
the heating power of the heater with the first heating power is less than the first
heating power.
- 39.The projection lens in accordance with clause 37 or 38, wherein
- the temperature control system controls at least one of the temperatures Tkm and Tkn such that the heating power of the respective heater and the exposure power of the
EUV light absorbed by the at least one temperature controlled body MBm or MBn is constant in time.
- 40.The projection lens in accordance with one of the clauses 33 to 39, wherein
- the absolute value of the difference between the zero cross temperatures T10mn, T20mn is more than 6K, expresses as abs(T10mn - T20mn) > 6K and/or wherein
- the lens is designed to be exposed with an exposure power of more than 8 W of EUV
light with a wavelength in a wavelength range of less than 50 nm.
- 41.The projection lens according to one of the clauses 33 to 40 with 4 or 6 reflective
optical elements in form of mirrors.
- 42.The projection lens according to one of the clauses 33 to 41, wherein one of the
mirror bodies MBn, MBm which are controlled by the temperature control system is connected to an actuator
for translational movement.
- 43.The projection lens according to one of the clauses 33 to 42, wherein at a time
before the projection lens is subjected to the exposure power of the EUV light the
temperature Tkn or Tkm of the at least one of the temperature controlled bodies MBn, MBm is controlled to its temperature value by cooling the tempering means with a first
cooling power.
- 44.The projection lens according to clause 43, wherein at a time when subjecting the
projection lens to the exposure power of the EUV light the cooling power of the tempering
means with the first cooling power is higher than the first cooling power.
- 45.The projection lens according to one of the clauses 33 to 44. wherein the tempering
means for heating the at least one of the bodies MBn, MBm comprises heating elements selected from the group consisting of IR light emitting
diodes, Peltier elements, optical fibers, light guide rods and IR lasers.
- 46. The projection lens according to clause 45, wherein the heating elements are arranged
in one dimension or in two dimensions at predefined spatial coordinates, forming a
grid structure.
- 47.The projection lens according to clause 45 or 46, wherein the heating elements
emitting or guiding IR radiation comprising an optical arrangement to configure the
IR radiation, the optical arrangement comprises arrangement elements selected from
the group consisting of collimator, focusing lens, adjustable lens, mirror and diffractive
optical element, wherein the arrangement elements may be tiltable around at least
on axis.
- 48.The projection lens according to one of the clauses 33 to 47, wherein the at least
one of the bodies MBn, MBm comprises a modification in or on the mirror body, the modification is selected from
the group consisting of recess, blind hole, defined surface roughness, diffractive
structure, spherical protrusion, spherical recess and surface curvature.
- 49.An EUV-lithographic projection exposure system, comprising a projection lens according
to one of the clauses 33 to 48.
- 50.A method to configure a projection lens of an EUV lithographic projection exposure
system, comprising the steps:
- determining the number of reflective optical elements Mi for projecting an object field on a reticle with an EUV projection light beam having
a wavelength of less than 50 nm onto an image field on a substrate with a predetermined
spatial resolution quality,
- determining the surface figure and surface shape of each reflective optical element
Mi based on the geometric data of the object field and the image field and the predetermined
spatial resolution quality,
- determining a substrate material for each reflective optical element Mi with its shape and size, wherein
- at least one substrate material is selected from a group of materials having a temperature
dependent coefficient of thermal expansion which is zero at a zero cross temperature
Tom,
- determining a maximum thermal load for each reflective optical element Mi which is expected during the projection of the object field onto the image field,
- determining a spatial temperature T(x,y,z) for each reflective optical element Mi based on its thermal load and evaluating the maximum and the average temperature
Timax and Tiav,
- selecting the at least one material with the zero cross temperature T0m based on the zero cross temperature T0m such that the maximum temperature or the average temperature Tm max and Tm av of the temperature T(x,y,z) of the optical element Mm related to the at least one material is lower than the zero cross temperature T0m, expressed as Tm max < T0m or Tm av < T0m and
- forming the mirrors and the lens with the selected materials.
- 51.The method to configure a projection lens as claimed in clause 50 with the step,
- selecting the at least one material such that the zero cross temperatures T0m is higher than the maximum temperature or the average temperature Tm max and Tm av increased by an absolute value of a respective manufacturing tolerance ΔT0m expressed as T0m > T m max + |ΔT0m | or T0m > Tm av + |ΔT0m |, wherein
- the material with the zero cross temperatures T0m vary regarding its real value of the zero cross temperature due to the manufacturing
tolerance ΔT0m such that the real value is within the intervals T0m ± ΔT0m.
- 52.The method as claimed in clause 51, wherein
- the one material with the zero cross temperature T0m comprises a second zero cross temperature T20m such that the absolute value of the difference between the zero cross temperature
and the second zero cross temperature is less than 40 K, expressed as abs (T0m - T20m) < 40 K.
- 53.The method as claimed in clause 52, wherein
- the material with the second zero cross temperature is used as substrate material
for at least one additional reflective optical element.
- 54.The method as claimed in one of the clauses 50 to 53 with the step,
- applying a heater and a temperature control system for controllably heating the at
least one material with the zero cross temperature.
- 55.A projection lens of an EUV-lithographic projection exposure system, comprising
- a plurality of reflective optical elements Mi, each comprising
- a body MBi and a reflective surface MSi for projecting an object field on a reticle onto an image field on a substrate if
the projection lens is exposed with an exposure power of EUV light with a wavelength
in a wavelength range of less than 50 nm, the EUV light being reflected from the reticle
when illuminated by an illumination system of the EUV-lithographic projection exposure
system,
- a support structure for passively or actively supporting the reflective optical elements
Mi, wherein the temperature of at least a part of the support structure is at a reference
temperature TRef,
- a heater for heating at least one optical element Mk on which a spatial temperature distribution ΔT(x,y,z) = (T(x,y,z)-TRef) relative to the reference temperature TRef is formed out when the projection lens is exposed with the exposure power without
heating the heater, the temperature distribution ΔT(x,y,z) having an average temperature
ΔTav and a maximum temperature ΔTmax, and
- a temperature control system for controlling the temperature of the at least one optical
element Mk to a temperature Tk, wherein the body MBk of the at least one heated reflective optical element Mk comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a temperature T0k at a temperature higher than the reference temperature TRef , and wherein
- before the exposure with the exposure power the optical element Mk has a temperature Tk by heating it with the heater, the temperature Tk is selected from the group consisting of Tk = T0k - ΔTav ; Tk = 2 ∗ T0k - TRef - ΔTav ; Tk = TRef + 3 ∗ (T0k - TRef)/2 -ΔTav ; Tk = T0k - ΔTmax ; Tk = 2 ∗ T0k - TRef - ΔTmax ; Tk = TRef + 3 ∗ (T0k - TRef)/2 - ΔTmax.
- 56.The projection lens according to clause 55, wherein the temperature Tk represents a temperature selected from the group consisting of
- a temperature TMSk of the reflective surface MSk of the optical element Mk,
- a temperature TMBk of the body MBk of the optical element Mk,
- a temperature given by a function of the temperature TMBk of the body MBk and/or the temperature TMSk of the reflective surface MSk and
- a temperature selected from a spatial temperature distribution of the body MBk or the reflective surface TMSk.
- 57. The projection lens according to one of the clauses 55 or 56, wherein
- the heater of the at least one heated optical element Mk is designed to homogenously heat the element Mk in at least one dimension.
- 58.The projection lens according to one of the clauses 55 to 57, wherein
- the temperature Tk of the optical element Mk is controlled to its value by heating the heater with a first heating power
- at a time before the projection lens is subjected to the exposure power of the EUV
light.
- 59.The projection lens according to clause 58, wherein
- the heating power of the heater is less than the first heating power while subjecting
the projection lens to the exposure power of the EUV light.
- 60.The projection lens according to one of the previous clauses 55 to 59, comprising
- a second heater for heating a second optical element M2k to a temperature T2k, wherein
- on the second optical element a second spatial temperature distribution ΔT2(x,y,z) = (T2(x,y,z)-TRef) relative to the reference temperature TRef is formed out when the projection lens is exposed with the exposure power without
heating the second heater, having an average temperature ΔT2av and a maximum temperature ΔT2max, wherein
- the body MB2k of the second optical element M2k comprises a material with a temperature dependent coefficient of thermal expansion
which is zero at a temperature T02k higher than the reference temperature, and wherein
- before the exposure with the exposure power the optical element M2k has a temperature T2k by heating it with the second heater, the temperature Tk is selected from the group consisting of : T2k = T02k -ΔT2av ; T2k = 2 ∗ T02k - TRef - ΔT2av ; T2k = TRef + 3 ∗ (T02k - TRef)/2 - ΔT2av ; T2k = T02k - ΔT2max ; T2k = 2 ∗ T02k - TRef - ΔT2max ; T2k = TRef + 3 ∗ (T02k - TRef)/2 - ΔT2max.
- 61.The projection lens according to clause 60, wherein the body MBk of the at least one heatable reflective optical element Mk and the body MB2k of the heatable second optical element M2k are made of the same material.
- 62.The projection lens according one of the clauses 60 or 61, wherein the absolute
value of the difference between the zero cross temperatures T0k, T02k of the heatable optical element and the second heatable optical element is more than
6K, expresses as abs(T0k - T02k)> 6K.
- 63.The projection lens according to one of the clauses 55 to 62, wherein the zero
cross temperature T0k of the at least one heatable optical element Mk is higher than the maximum of the highest reference temperature TRef and the average or maximum temperature ΔTav + TRef or ΔTmax + TRef based on the respective spatial temperature distribution ΔT(x,y,z), expressed as
T0k > max(TRef, ΔTav + TRef) or T0k > max(TRef, ΔTmax + TRef).
- 64.The projection lens according to one of the clauses 55 to 63 with 4 or 6 reflective
optical elements in form of mirrors.
- 65.The projection lens according to one of the clauses 55 to 64, wherein the at least
one optical element Mk heatable by the heater is connected to an actuator for its translational movement.
- 66.The projection lens according to one of the clauses 55 to 66. wherein the heater
for heating the at least one optical element Mk comprises heating elements selected from the group consisting of IR light emitting
diodes, Peltier elements, optical fibers, light guide rods and IR lasers.
- 67. The projection lens according to clause 66, wherein the heating elements are arranged
in one dimension or in two dimensions at predefined spatial coordinates, forming a
grid structure.
- 68. The projection lens according to clause 66 or 67, wherein the heating elements
emitting or guiding IR radiation comprising an optical arrangement to configure the
IR radiation, the optical arrangement comprises arrangement elements selected from
the group consisting of collimator, focusing lens, adjustable lens, mirror and diffractive
optical element, wherein the arrangement elements may be tiltable around at least
on axis.
- 69. The projection lens according to one of the clauses 66 to 68, wherein the at least
one optical element Mk comprises a modification in or on the mirror body MBk, the modification is selected from the group consisting of recess, blind hole, defined
surface roughness, diffractive structure, spherical protrusion, spherical recess and
surface curvature.
- 70.An EUV-lithographic projection exposure system, comprising a projection lens according
to one of the clauses 55 to 69.